Connectors for making connections between analyte sensors and other devices

ABSTRACT

Glucose monitoring devices and related systems and methods, the glucose monitoring devices including a sensor electronics unit having a housing and a printed circuit board disposed within the housing, a transcutaneous glucose sensor assembly, and a conductive sensor connector. The printed circuit board includes a first electrical contact, the transcutaneous glucose sensor assembly includes a distal portion having a working electrode and proximal portion having a working-electrode contact in electrical communication with the working electrode, and the conductive sensor connector electrically connects the working-electrode contact with the first electrical contact. Further, the conductive sensor connector extends through a hole in the proximal portion of the transcutaneous glucose sensor assembly and through a hole in the printed circuit board.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to Ser. No. 17/140,417, filed Jan. 4,2021 and published as 2021/0128027, which is a continuation of Ser. No.16/443,468 filed Jun. 17, 2019 and now U.S. Pat. No. 10,888,257, whichis a continuation of Ser. No. 15/728,597 filed Oct. 10, 2017 and nowU.S. Pat. No. 10,321,863, which is a continuation of Ser. No. 15/047,476filed Feb. 18, 2016 and now U.S. Pat. No. 9,782,112, which is acontinuation of Ser. No. 14/685,304 filed Apr. 13, 2015 and now U.S.Pat. No. 9,271,670, which is a continuation of Ser. No. 13/526,136 filedJun. 18, 2012 and now U.S. Pat. No. 9,007,781, which claims priority to61/498,142, filed Jun. 17, 2011, the disclosures of which areincorporated by reference herein.

INTRODUCTION

In many instances it is desirable or necessary to regularly monitor theconcentration of particular constituents in a fluid. A number of systemsare available that analyze the constituents of bodily fluids such asblood, urine and saliva. Examples of such systems may be configured tomonitor the level of particular medically significant fluidconstituents, such as, for example, cholesterol, ketones, vitamins,proteins, and various metabolites or blood sugars, such as glucose.Diagnosis and management of patients suffering from diabetes mellitus, adisorder of the pancreas where insufficient production of insulinprevents normal regulation of blood sugar levels, generally requirescareful monitoring of blood glucose levels on a daily basis.

A number of systems that allow individuals to easily monitor their bloodglucose are currently available. For example, a person may obtain ablood sample by withdrawing blood from a blood source in his or herbody, such as a vein, using a needle and syringe, for example, or bylancing a portion of his or her skin, using a lancing device, forexample, to make blood available external to the skin, to obtain thenecessary sample volume for in vitro testing. The person may then applythe blood sample to a test strip, whereupon suitable detection methods,such as calorimetric, electrochemical, or photometric detection methods,for example, may be used to determine the person's actual blood glucoselevel. The foregoing procedure provides a blood glucose concentrationfor a particular or discrete point in time, and thus, must be repeatedperiodically when the user actively initiates the procedure, in order tomonitor blood glucose over a longer period.

In addition to the discrete or periodic, in vitro, bloodglucose-monitoring systems described above, there are at least partiallyimplantable, or in vivo, blood glucose-monitoring systems, which areconstructed to provide continuous or automatic in vivo measurement of anindividual's blood glucose concentration. Such in vivo analytemonitoring devices are constructed to provide for continuous orautomatic monitoring of analytes, such as glucose, in the blood streamor interstitial fluid while the in vivo analyte monitoring device ispositioned at least partially in the body of a user. Such devicesinclude analyte sensors, e.g., electrochemical sensors, at least aportion of which are operably positioned in a blood vessel or in thesubcutaneous tissue of a user, or elsewhere, for monitoring/detection.

While continuous or automatic glucose monitoring is desirable, there areseveral challenges associated with manufacturing sensors constructed forin vivo use. In addition, attaching such sensors to other systemcomponents such as electronics units, e.g., sensor control units, posesadditional challenges, particularly where two or more electrodes andtheir respective conductive traces are positioned on different surfacesof the sensor, e.g., on opposing substrate surfaces. Accordingly,further development of manufacturing techniques and methods, as well asanalyte monitoring devices, systems, and kits employing the same, aredesirable and provided herein.

SUMMARY

Analyte sensor connectors that connect analyte sensors, e.g., conductivemembers of analyte sensors, to other devices such as sensor electronicsunits, e.g., sensor control units, are provided. Also provided aresystems that include analyte sensors, analyte sensor connectors, andanalyte sensor electronics units, as well as methods of establishing andmaintaining connections between analyte sensors and analyte sensorelectronics units, and methods of analyte monitoring/detection. Alsoprovided are methods of making analyte sensor connectors and systemsthat include analyte sensor connectors.

Embodiments of the present disclosure relate to analyte monitoringand/or detection devices and systems which utilize one or more sensorconnectors, e.g., one or more rivets, to physically connect an analytesensor, e.g., an in vivo or in vitro analyte sensor having one or moreelectrodes to an electronics unit such as a sensor control unit. Alsoprovided, are systems and devices which utilize one or more conductivesensor connectors, e.g., conductive rivets, to electrically connect ananalyte sensor, e.g., an in vivo or in vitro analyte sensor, having oneor more electrodes to an electronics unit such as a sensor control unit,e.g., by electrically connecting one or more electrodes disposed on afirst surface of the analyte sensor with one or more electrical contactsdisposed on a second surface of the analyte sensor or a surface of theelectronics unit.

Methods of making and using the analyte monitoring systems and devices,as well as methods of analyte monitoring and kits are provided. Alsoprovided are analyte sensors and analyte sensor precursors along withmethods of making and using the same.

BRIEF DESCRIPTION OF THE DRAWINGS

A detailed description of various embodiments of the present disclosureis provided herein with reference to the accompanying drawings, whichare briefly described below. The drawings are illustrative and are notnecessarily drawn to scale. The drawings illustrate various embodimentsof the present disclosure and may illustrate one or more embodiment(s)or example(s) of the present disclosure in whole or in part. A referencenumeral, letter, and/or symbol that is used in one drawing to refer to aparticular element may be used in another drawing to refer to a likeelement.

FIG. 1A shows a cross-sectional view of a distal portion of an analytesensor according to the present disclosure.

FIG. 1B shows a cross-section of the analyte sensor depicted in FIG. 1Ataken along lines A-A.

FIG. 1C shows a cross-section of an alternative embodiment of theanalyte sensor depicted in FIG. 1A taken along lines A-A.

FIG. 1D shows a top view of the analyte sensor depicted in FIGS. 1A and1B. The insulative layers are not shown so that the two conductivelayers are visible.

FIGS. 2-4 show cross-sectional views of distal portions of embodimentsof double-sided analyte sensors which may be utilized in connection withembodiments of the present disclosure.

FIG. 5 shows a cross-sectional view of a distal portion of anotherembodiment of a double-sided analyte sensor which may be utilized inconnection with embodiments of the present disclosure.

FIG. 6 provides an exploded view of an analyte sensor assembly accordingto one embodiment of the present disclosure.

FIG. 7 provides a top transparent view of an analyte sensor assemblyaccording to one embodiment of the present disclosure, a top view of theanalyte sensor assembly showing a counter electrode, and a bottom viewof the analyte sensor construction showing reference and workingelectrodes. In some cases, substrate and dielectric layers are shownopaque for clarity.

FIG. 8 shows a bottom view of a first sensor layer, a working electrodelayer positioned on a dielectric substrate, of the analyte sensorassembly shown in FIG. 7.

FIG. 9 shows a bottom view of a second sensor layer, a dielectric layer,covering a portion of the working electrode layer shown in FIG. 8.

FIG. 10 shows a bottom view of a third sensor layer, a referenceelectrode layer, positioned over (relative to the plane of the page) thesecond sensor layer shown in FIG. 9.

FIG. 11 shows a Ag/AgC1 layer positioned on the reference electrodelayer shown in FIG. 10.

FIG. 12 shows a bottom view of a fourth sensor layer, a dielectriclayer, positioned over (relative to the plane of the page) the Ag/AgC1layer and the working and reference electrode layers as shown in FIGS.8-11.

FIG. 13 shows a top view of a fifth sensor layer, a counter electrodelayer, positioned over (relative to the plane of the page) the layersshown in FIGS. 8-12.

FIG. 14 shows a top view of a sixth sensor layer, a dielectric layer,positioned over (relative to the plane of the page) portions of thecounter electrode layer shown in FIG. 13.

FIG. 15A shows a side view of one embodiment of a rivet which may beused in connection with the present disclosure.

FIG. 15B shows a cross-section taken along section L-L of FIG. 15A.

FIG. 15C shows a bottom perspective view of the rivet depicted in FIG.15A.

FIG. 15D shows a side view of one embodiment of a rivet which may beused in connection with the present disclosure.

FIG. 15E shows a cross-section taken along section L-L of FIG. 15D.

FIG. 15F shows a bottom perspective view of the rivet depicted in FIG.15D.

FIG. 15G shows a side view of one embodiment of a rivet which may beused in connection with the present disclosure.

FIG. 15H shows a cross-section taken along section L-L of FIG. 15G.

FIG. 151 shows a bottom perspective view of the rivet depicted in FIG.15G.

FIG. 15) shows a side view of one embodiment of a rivet which may beused in connection with the present disclosure.

FIG. 15K shows a cross-section taken along section L-L of FIG. 15J.

FIG. 15L shows a bottom perspective view of the rivet depicted in FIG.15J.

FIG. 15M shows side views of various rivet embodiments which may be usedin connection with the present disclosure.

FIGS. 16A and 16B show a generalized sensor connector concept accordingto one embodiment of the present disclosure. 1) The conductive sensorconnector, e.g., a conductive rivet, makes contact with an electricalcontact on top of an analyte sensor. 2) The conductive sensor connectormechanically holds contacts together making contact between electricalcontacts on the bottom of the analyte sensor and electrical contacts onthe top of a printed circuit board (PCB). 3) The conductive connector,e.g., rivet, is formed and makes contact with an electrical contact onthe bottom of the PCB thereby providing an electrical connection betweenthe electrical contact on top of the analyte sensor and the electricalcontact on the bottom of the PCB. (16A) provides an exploded view and amirrored exploded view of a sensor attached via a rivet to a PCB. (16B)provides another perspective of the exploded view shown in (A).

FIG. 17 shows a schematic diagram of an embodiment of an analyte sensoraccording to some embodiments of the present disclosure.

FIG. 18 shows a block diagram of an embodiment of an analyte monitoringsystem according to embodiments of the present disclosure.

FIG. 19 shows a block diagram of an embodiment of a data processing unitof the analyte monitoring system shown in FIG. 18.

FIG. 20 shows a block diagram of an embodiment of the primary receiverunit of the analyte monitoring system of FIG. 18.

FIGS. 21A and 21B show a top perspective view and a bottom perspectiveview respectively of a sensor control unit insertion assembly accordingto one embodiment of the present disclosure.

FIG. 22 provides a view which visually identifies the various componentsof the sensor control unit insertion assembly depicted in FIGS. 21A and21B.

FIGS. 23A-23G provide an exploded view (23A), top view (23B), side view(23C), bottom view (23D), cross-section (23E) taken along section A-A of(23B), a top perspective view (23F) and a bottom perspective view (23G),of a portion of the sensor control unit insertion assembly depicted inFIGS. 21A and 21B including a PCB assembly, sensor support, analytesensor, rivet and sensor insertion device. The analyte sensor is shownprior to cutting, e.g., along the cut line shown in FIG. 7, to removeexcess sensor material.

FIGS. 24A-24G provide a top view (24A) and a side view (24B) of theportion of the sensor control unit insertion assembly depicted in FIGS.24A-24G. Here, the analyte sensor is shown after cutting, e.g., alongthe cut line shown in FIG. 7, to remove excess sensor material. Alsoprovided, is a top view (24C), a side view (24D), a bottom view (24E), atop perspective view (24F) and a bottom perspective view (24G) of aportion of the sensor control unit insertion assembly depicted in FIGS.21A and 21B including the PCB assembly, sensor support, analyte sensor,rivet, sensor insertion device and overmold structure. An optionalthermistor of the PCB assembly is shown in a partially foldedconfiguration.

FIGS. 25A-25E provide a top view (25A), a side view (25B), a bottom view(25C), a top perspective view (25D) and a bottom perspective view (25E)of a portion of the sensor control unit insertion assembly depicted inFIGS. 21A and 21B including the PCB assembly, sensor support, analytesensor, rivet, sensor insertion device and overmold structure. Theoptional thermistor of the PCB assembly is shown in completely foldedconfiguration.

FIGS. 26A-26E provide a top view (26A), a side view (26B), a bottom view(26C), a top perspective view (26D) and a bottom perspective view (26E)of the sensor control unit insertion assembly depicted in FIGS. 21A and21B, including the overmold structure and the skin patch.

FIG. 27 provides a perspective view of an analyte sensor according toone embodiment of the present disclosure, wherein the analyte sensor isshown in a bent configuration suitable for insertion in connection witha sensor control unit insertion assembly as described herein. Theanalyte sensor is shown prior to cutting, e.g., along the cut line shownin FIG. 7.

DETAILED DESCRIPTION

Before the embodiments of the present disclosure are described, it is tobe understood that this invention is not limited to particularembodiments described, as such may, of course, vary. It is also to beunderstood that the terminology used herein is for the purpose ofdescribing particular embodiments only, and is not intended to belimiting, since the scope of the embodiments of the invention will beembodied by the appended claims.

Where a range of values is provided, it is understood that eachintervening value, to the tenth of the unit of the lower limit unlessthe context clearly dictates otherwise, between the upper and lowerlimits of that range is also specifically disclosed. Each smaller rangebetween any stated value or intervening value in a stated range and anyother stated or intervening value in that stated range is encompassedwithin the invention. The upper and lower limits of these smaller rangesmay independently be included or excluded in the range, and each rangewhere either, neither or both limits are included in the smaller rangesis also encompassed within the invention, subject to any specificallyexcluded limit in the stated range. Where the stated range includes oneor both of the limits, ranges excluding either or both of those includedlimits are also included in the invention.

In the description of the invention herein, it will be understood that aword appearing in the singular encompasses its plural counterpart, and aword appearing in the plural encompasses its singular counterpart,unless implicitly or explicitly understood or stated otherwise. Merelyby way of example, reference to “an” or “the” “analyte” encompasses asingle analyte, as well as a combination and/or mixture of two or moredifferent analytes, reference to “a” or “the” “concentration value”encompasses a single concentration value, as well as two or moreconcentration values, and the like, unless implicitly or explicitlyunderstood or stated otherwise. Further, it will be understood that forany given component described herein, any of the possible candidates oralternatives listed for that component, may generally be usedindividually or in combination with one another, unless implicitly orexplicitly understood or stated otherwise. Additionally, it will beunderstood that any list of such candidates or alternatives, is merelyillustrative, not limiting, unless implicitly or explicitly understoodor stated otherwise.

It is further noted that the claims may be drafted to exclude anyrecited element. As such, this statement is intended to serve asantecedent basis for use of such exclusive terminology as “solely,”“only” and the like in connection with the recitation of claim elements,or use of a “negative” limitation.

Various terms are described below to facilitate an understanding of theinvention. It will be understood that a corresponding description ofthese various terms applies to corresponding linguistic or grammaticalvariations or forms of these various terms. It will also be understoodthat the invention is not limited to the terminology used herein, or thedescriptions thereof, for the description of particular embodiments.Merely by way of example, the invention is not limited to particularanalytes, bodily or tissue fluids, blood or capillary blood, or sensorconstructs or usages, unless implicitly or explicitly understood orstated otherwise, as such may vary.

To the extent any definition of a term defined herein conflicts with adefinition of a term in an application or reference incorporated byreference herein, the instant application shall control.

The publications discussed herein are provided solely for theirdisclosure prior to the filing date of the application. Nothing hereinis to be construed as an admission that the embodiments of the inventionare not entitled to antedate such publication by virtue of priorinvention. Further, the dates of publication provided may be differentfrom the actual publication dates which may need to be independentlyconfirmed.

Generally, embodiments of the present disclosure relate to methods,devices systems, and related kits for detecting and/or monitoring atleast one analyte, such as glucose, in body fluid. Embodiments relate tothe continuous and/or automatic in vivo detection and/or monitoring ofthe level of one or more analytes using a continuous analyte monitoringsystem that includes an analyte sensor for the in vivo detection and/ormonitoring of at least one analyte, such as glucose, lactate, oxygen,ketones, and the like, in a body fluid. Embodiments include whollyimplantable analyte sensors and transcutaneous analyte sensors in whichonly a portion of the sensor is positioned under the skin and a portionof the sensor resides above the skin, e.g., for contact to anelectronics unit (e.g., a sensor control unit), a communication device,(e.g., a transmitter, receiver, transceiver, radio frequencyidentification (RFID) tag or reader), a processor, etc. Additionalinformation regarding RFID tags and readers is provided, for example, inU.S. Patent Application Publication No. 2010/0063374, the disclosure ofwhich is incorporated by reference herein.

At least a portion of a sensor may be, for example, subcutaneouslypositionable in a patient for the continuous or semi-continuousmonitoring of a level of an analyte in a patient's interstitial fluid.For the purposes of this description, the term continuous monitoringencompasses semi-continuous monitoring unless noted otherwise. Thesensor response, for example if obtained from non-blood samples, may becorrelated and/or converted to analyte levels in blood or other fluids.In certain embodiments, an analyte sensor may be positioned in contactwith interstitial fluid to detect the level of glucose, which detectedglucose may be used to infer the glucose level in the patient'sbloodstream. Analyte sensors may be insertable into a vein, artery, orother portion of the body containing fluid. Embodiments of the analytesensors of the subject disclosure may be configured to automaticallymonitor the level of the analyte over a time period which may range fromminutes, hours, days, weeks, or longer, e.g., 14 days or longer, such as21 days or 30 days or more.

Embodiments of the present disclosure relate to analytedetection/monitoring systems and devices which utilize analyte sensorsincluding single-sided and double-sided analyte sensors wherein at leastsome of the electrodes of the sensor are in a stacked configuration, orare in a side-by-side configuration, and in some embodiments a sensormay have some electrodes side by side on a substrate surface, and atleast one other electrode on the opposing side of the substrate whichmay be side by side if more than one or layered one on top of the otheron the opposing substrate surface, or a combination thereof.

Embodiments of the present disclosure relate to analytedetection/monitoring systems and devices which utilize one or moresensor connectors, e.g., one or more rivets, to attach an analyte sensorhaving one or more electrodes to an electronics unit. Also provided, aresystems and devices which utilize one or more conductive sensorconnectors, e.g., one or more conductive rivets, to electrically connectan analyte sensor having one or more electrodes to an electronics unit,e.g., by electrically connecting one or more electrodes disposed on afirst surface of the analyte sensor with one or more electrical contactsdisposed on a second surface of the analyte sensor or a surface of theelectronics unit. Methods of making and using the analytedetecting/monitoring systems and devices, as well as kits provided inconnection with same, are disclosed herein. In addition, the presentdisclosure provides analyte sensors and analyte sensor precursors alongwith methods of making and using the same.

Sensor Connectors for Attaching an Analyte Sensor to an Electronics Unit

One or more sensor connectors may be utilized to attach an analytesensor such as a glucose sensor having one or more electrodes to anelectronics unit such as a sensor control unit of an analytedetection/monitoring system. Such sensor connectors may physicallyconnect, electrically connect, or both physically and electricallyconnect the analyte sensor and the electronics unit. For example, wherethe analyte sensor includes at least an insulative base layer, anelectrode, and an insulative layer, as described in greater detailbelow, the one or more sensor connectors may physically connect one ormore of the insulative base layer, the electrode, and the insulativelayer to the electronics unit. Where the analyte sensor includes aplurality of insulative layers and electrodes, more than one of theinsulative layers and/or electrodes may be physically connected to theelectronics unit via one or more sensor connectors. Where a connectionthat is both physical and electrical is provided, one or more conductivesensor connectors physically and electrically connects an electrode ofthe sensor to an electronics unit, e.g., by physically contacting boththe electrode and an electrical contact of the electronics unit.

Regardless of the configuration of a sensor, e.g., whether it be singlesided or double sided as described in greater detail below, a sensorconnector may be used to physically or electrically, or physically andelectrically connect the sensor, and more particularly the electricalcontacts of the sensor, with conductive contacts of a sensor electronicsunit. In many embodiments, the sensor is at least partially insertedinto the body of a user (i.e., in vivo), and the sensor control unit ispositioned outside the body (i.e., ex-vivo).

Suitable sensor connectors for use in the disclosed embodiments may takea variety of forms, including, but not limited to: rivets, clamps,screws, nails, pins, posts, vias, other connectors or attachmentmechanisms known in the art, and combinations thereof.

Sensor connectors, e.g., rivets, suitable for use in connection with thepresent disclosure may be made from a variety of suitable materialsdepending on the particular application and the materials to beconnected, e.g., joined. For example, where the sensor connector is onewhich physically connects the analyte sensor and the electronics unit,the sensor connector, e.g., rivet, may be made from any suitablenon-conductive material, e.g, polycarbonate,acrylonitrile-butadiene-styrene (ABS),polycarbonate-acrylonitrile-butadiene-styrene (PC-ABS), polyethylene,and the like. It should be noted that conductive materials as describedbelow may also be used to physically connect an analyte sensor and anelectronics unit without electrically connecting the analyte sensor andthe electronics unit or sensor control unit. Where the sensor connectoris a conductive sensor connector which physically and electricallyconnects the analyte sensor and the electronics unit or sensor controlunit, the conductive sensor connector, e.g., conductive rivet, may bemade from any suitable conductive material, e.g., a metallic conductivematerial (e.g., gold, silver, platinum, aluminum, copper, brass, etc.,or tinplated or gold-plated versions thereof), carbon, or a conductivepolymer (e.g., a conductive carbon polymer).

For embodiments utilizing a rivet, e.g., a conductive or non-conductiverivet, connection via the rivet may be made, for example, by insertingthe rivet through a hole in a component of the analyte sensor, e.g., anelectrode, an insulative base substrate or an insulative layer, andthrough a hole in a component of the electronics unit, e.g., a PCB or anelectrical contact, followed by deformation of the rivet and expansionat the buck-tail end as a result of the application of force to therivet head which joins the analyte sensor and the electronics unit toprovide a physical and/or electrical connection between a component ofthe analyte sensor and the electronics unit. Application of the rivetmay be accomplished using any of a variety of riveting processes knownto those of ordinary skill in the art. For example, a spiral forming,impact forming or orbit forming process may be utilized.

In addition to providing a physical and/or electrical connection, thesensor connector, e.g., a rivet, may provide alignment or registrationbetween an analyte sensor and an electronics unit, e.g., a PCB of anelectronics unit. In addition, use of a sensor connector, e.g., a rivet,allows for a relatively low temperature connection or attachmentprocess. Such a process may be beneficial when compared with a highertemperature process which has the potential to negatively affect thesensor materials and/or sensing chemistry. For example, connecting asensor with an electronics unit using an adhesive, such as ACF(anisotropic conductive film) or ACA (anisotropic conductive adhesive)may require high temperatures to create a bond. Accordingly, embodimentsof the present disclosure which utilize a sensor connector, e.g., arivet, attachment mechanism provides advantages over other sensorattachment mechanisms and methods.

An embodiment of a sensor connector is a rivet connector. A rivetconnector includes a head portion and a body or shaft portionterminating at a buck-tail end opposite the head portion, and in someembodiments includes a head portion at a first end and a second headportion at a second end (e.g., as a result of deformation of thebuck-tail end during application of the rivet), and an intermediate bodyportion therebetween. Exemplary rivet connectors are shown at FIGS.15A-15M. FIGS. 15A-15C show an embodiment which includes a head portionand body portion, but as noted above a second head may also be included.Rivet 600 includes a head 601 and a shaft 602 positioned, for example,perpendicular thereto. The angle formed by the head 601 and shaft 602 isdepicted as 90 degrees in FIGS. 15A-15C, but may range from 0 to 180degrees, for example, it may be 10 degrees, 20 degrees, 30 degrees, 40degrees, 50 degrees, 60 degrees, 70 degrees, 80 degrees, 90 degrees, 100degrees, 110 degrees, 120 degrees, 130 degrees, 140 degrees, 150degrees, 160 degrees, 170 degrees, 180 degrees or an increment thereof.In some embodiments, the angle formed by the head and shaft is between90 degrees and 10 degrees, e.g., between 80 degrees and 10 degrees,between 70 degrees and 10 degrees, between 60 degrees and 10 degrees,between 50 degrees and 10 degrees, between 40 degrees and 10 degrees,between 30 degrees and 10 degrees or between 20 degrees and 10 degrees.

FIGS. 15D-15F show an embodiment, which like FIGS. 15A-15C, includes ahead 601 and shaft 602. In this embodiment, the angle (indicated at604), formed by the head 601 and shaft 602 is less than 90 degrees. Suchan embodiment allows room for compression of the rivet head 601, e.g.,during deformation of the rivet as a result of the application of forceto rivet head 601 during application of the rivet 600, for example, toan analyte sensor and an electronics unit.

FIGS. 15G-15I show an embodiment, which like FIGS. 15A-15C, includes ahead 601 and shaft 602. The rivet 600 is shown with an optional partialhole or lumen 603 opposite the head and extending at least partiallythrough the shaft 602. Partial hole 603 allows for expansion or flaringof the shaft 602 at the end opposite the head 601 upon deformation ofthe rivet, e.g., as a result of the application of force to head 601during application of the rivet 600, for example, to an analyte sensorand an electronics unit. This flaring facilitates connection of theanalyte sensor and the electronics unit via the rivet as a result ofcontact between the flared rivet end and an area of the component of theanalyte sensor or electronics unit adjacent the hole through which therivet is inserted. FIGS. 15G-15I also show the angle 604 formed by thehead 601 and shaft 602 is less than 90 degrees as discussed above. Whilepartial hole or lumen 603 is depicted as terminating at a point at anend opposite the opening of the hole or lumen, many other configurationsare possible. For example, the partial hole or lumen 603 could have arectangular or cylindrical shape. In addition, in some embodiments, ahole or lumen may extend completely through the rivet.

FIGS. 15J-15L show an embodiment, which includes both an optionalpartial hole or lumen 603 opposite the head 601 and extending at leastpartially through the shaft 602 as discussed above and a configurationin which the angle 604 formed by the head 601 and shaft 602 is less than90 degrees as discussed above. In addition, FIGS. 15J-15L show anoptional beveled end 605 of shaft 602 at the end opposite head 601.

The sensor connector rivet head can be a round head rivet, flat headrivet, brazier head rivet, countersunk head rivet, universal rivet, orother construction. Exemplary rivets which may be used as sensorconnector rivets are shown at FIG. 15M. In some embodiments, aconductive rivet which may be used as a sensor connector rivet includesone or more conductive portions and one or more non-conductive portions.For example, in some embodiments, a sensor connector rivet includes aconductive head and an insulative shaft (or vice versa). In someembodiments, a conductive rivet includes a conductive center core withnon-conductive material positioned external to the conductive centercore.

In some embodiments, the rivet head 601 contacts a sensor electronicsunit and therefore includes an electronics contacting portion, and theshaft contacts a sensor and therefore includes a sensor contactingportion. The shaft 602 connects to a sensor, and in many embodimentsconnects by engagement through a hole or via of a sensor.

In other embodiments, the rivet head 601 contacts a sensor and thereforeincludes a sensor contacting portion, and the shaft contacts a sensorelectronics unit and therefore includes a sensor electronics contactingportion. The shaft 602 connects to a sensor electronics unit, and inmany embodiments connects by engagement through a hole or via of asensor electronics unit.

Shaft 602 may have a uniform width, or may be variable at least alongsome of its length, e.g., as shown in FIGS. 15J-15L, wherein the shaftend opposite the rivet head 601 has a beveled end or edge 605. Someembodiments include a shaft that has a continually reduced width alongits entire length from the head contacting end to its opposing end, orvice versa. FIGS. 15J-15L show a narrowing shaft end relative to thewidth of the rest of the shaft, at the shaft end that is opposite theshaft head contacting end. This end may alternatively be flared relativeto the width of the rest of the shaft.

A sensor connector rivet may be rigid or may be flexible. In someembodiments, a rivet is compressible. A rivet may include some rigidportions and some compressible portions.

A sensor connector rivet may be solid or partially open, for example asdescribed above with reference to FIGS. 15G-15I and 15J-15L, wherein thesensor connector rivet includes an optional partial hole or lumen 603opposite the head and extending at least partially through the shaft602. In such instances, the diameter of the partial hole or lumen maybe, for example, from about 0.018 in to about 0.022 in, e.g., about0.020 in. The hole or lumen depth may be, for example, from about 0.032in to about 0.038 in, e.g., about 0.035 in.

Exemplary sensor connector rivet dimensions may be as follows: the rivethead may have a diameter of about 0.110 in to about 0.134 in, e.g.,about 0.122 in; the rivet head may have a head thickness of about 0.018in to about 0.022 in, e.g., 0.020 in; the rivet shaft may have a shaftlength of about 0.056 in to about 0.070 in e.g., about 0.063 in; and therivet shaft may have a diameter of about 0.035 to about 0.043, e.g.,about 0.039 in. One of ordinary skill in the art will understand thatthese dimensions may be adjusted, e.g., to accommodate changes inanalyte sensor and/or electronics unit dimensions. In addition, whilethe figures depict a rivet having a round rivet head and a generallycylindrical shaft, one of ordinary skill in the art will recognize thatother shapes and configurations may be utilized.

An analyte sensor and an associated sensor electronics unit as describedherein may be provided to a user of the sensor or a health care providerin several different configurations prior to insertion of the analytesensor or a portion thereof in the user. For example, the analyte sensormay be provided attached to the sensor electronics unit via one or moresensor connectors, e.g., one or more rivets. In some embodiments, theanalyte sensor and the sensor electronics unit may be providedseparately, i.e., unattached, with one or both of the analyte sensor andthe sensor electronics unit including one or more sensor connectors,e.g., a rivet positioned in a through hole or via in the analyte sensorand/or the sensor electronics unit. The analyte sensor and the sensorelectronics unit may then be connected via the one or more sensorconnectors either prior to or during insertion of the analyte sensor. Insome embodiments, the analyte sensor and the sensor electronics unit maybe provided separately with one or more sensor connectors also providedseparately. The analyte sensor and sensor electronics unit can then beconnected using the one or more sensor connectors, e.g., prior to orduring insertion. In accordance with the above configurations, one ormore of the analyte sensor, the sensor electronics unit and the one ormore sensor connectors may be packaged separately or together.

Single-Sided Analyte Sensors Attached or Attachable to Electronics Units

The sensor connectors described herein can be used to connect manydifferent types of sensors to sensor electronic units. Sensors includewire sensors and planar sensors. Wire sensors generally include asubstrate (dielectric material) and electrodes (conductive material) andmay include a core conductive wire that may be a working electrode, andone or more other conductive wires which may wrapped or coiled around atleast a length of the core wire and serve as a reference electrode,counter electrode or reference/counter electrode. For exemplarypurposes, electrochemical planar sensors are primarily described, wheresuch description is in no way intended to limit the invention.

In some embodiments, the present disclosure provides an analytedetection/monitoring device including a single-sided analyte sensorattached via one or more sensor connectors, e.g., one or more rivets, toan electronics unit such as a sensor control unit, e.g., to a printedcircuit board of an electronics unit or sensor control unit. As usedherein, the term “single-sided analyte sensor” refers to an analytesensor having one or more electrodes which may include, e.g, aconductive trace, positioned on one side of an at least generally planarinsulative base substrate with or without an intermediary layer and noelectrodes positioned on the opposing side of the insulative basesubstrate with or without an intermediary layer. Such sensors may have astacked configuration, e.g., alternating conductive and insulativelayers, or a side-by-side configuration, but in any event all of theelectrodes and their respective conductive traces are on the same sideof the insulating base substrate. In other words, the one or moreelectrodes may be provided on the same side of the insulative basesubstrate in either a layered or co-planar manner.

Embodiments of a single-sided, stacked sensor configuration which may beutilized in connection with the present disclosure are described, forexample, in U.S. Application No. 2011/0021889, the disclosure of whichis incorporated by reference herein in its entirety and for allpurposes.

The use of a sensor connector as described herein, e.g., a rivet, as amechanism for attachment of an analyte sensor to an electronics unit,such as a sensor control unit, e.g., to a PCB of the sensor controlunit, may result in improved attachment of the analyte sensor to thesensor control unit as compared with other attachment methods, e.g., theuse of one or more adhesives. As discussed herein, the sensor connector,e.g., rivet, may be made from a variety of suitable materials dependingon the particular embodiment. For example, in some embodiments, thesensor connector, e.g., rivet, physically connects the single-sidedanalyte sensor and the electronics unit. In other embodiments, thesensor connector, e.g., rivet, physically and electrically connects thesingle-sided analyte sensor and the electronics unit. Where the sensorconnector, e.g., rivet, physically connects the analyte sensor and theelectronics unit, the sensor connector, e.g., rivet, may be made fromany suitable conductive or non-conductive material. Where the sensorconnector, e.g., a conductive rivet, physically and electricallyconnects the single-sided analyte sensor and the electronics unit, thesensor connector, e.g., a conductive rivet, may be made from anysuitable conductive material, e.g., copper. In some embodiments, thesensor connector, e.g., a conductive rivet, may conduct an electricalsignal from an electrode, e.g. a conductive trace of an electrode,positioned on one side of the single-sided analyte sensor to the otherside of the single-sided analyte sensor, e.g., for electrical connectionwith a PCB to which the single-sided analyte sensor is attached. Where aplurality of electrodes is present, one or more of the plurality ofelectrodes may be electrically connected to the PCB via a correspondingconductive sensor connector, e.g., a conductive rivet. For example, ananalyte sensor having three electrodes may include 1, 2 or 3 conductivesensor connectors, e.g., rivets; an analyte sensor having fourelectrodes may include 1, 2, 3 or 4 conductive sensor connectors, e.g.,conductive rivets; etc. Additional non-conductive and conductive sensorconnector, e.g., rivet, materials are discussed herein.

Double-Sided Analyte Sensors Attached or Attachable to Electronics Units

In some embodiments, an analyte detection/monitoring device including adouble-sided analyte sensor attached via one or more sensor connectors,e.g., rivets, to an electronics unit, such as a sensor control unit,e.g., to a PCB of the sensor control unit, is provided. As used herein,the term “double-sided analyte sensor” refers to an analyte sensorhaving one or more electrodes which may include, e.g., a conductivetrace, positioned on one side of an at least generally planar insulativebase substrate with or without an intermediary layer and one or moreelectrodes positioned on the opposite side of the insulative basesubstrate with or without an intermediary layer. In a double-sidedanalyte sensor, at least one electrode, e.g., a conductive trace of atleast one electrode, is at least partially exposed for electricalconnection on one face of the at least generally planar insulative basesubstrate and at least one electrode, e.g., a conductive trace of atleast one electrode, is at least partially exposed on the opposite faceof the at least generally planar insulative base substrate forelectrical connection. Such sensors may have a stacked configuration,e.g., alternating conductive and insulative layers, or a side-by-sideconfiguration. In other words, the one or more electrodes may beprovided on opposite sides of the at least generally planar insulativebase substrate in either a layered or co-planar manner.

Embodiments of a double-sided, stacked sensor configuration which may beutilized in connection with the present disclosure are described belowwith reference to FIGS. 2-4. FIG. 2 shows a cross-sectional view of adistal portion of a double-sided analyte sensor 20. Analyte sensor 20includes an at least generally planar insulative base substrate 21,e.g., an at least generally planar dielectric base substrate, having afirst conductive layer 22 which substantially covers the entirety of afirst surface area, e.g., the top surface area, of insulative substrate21, i.e., the conductive layer substantially extends the entire lengthof the substrate to the distal edge and across the entire width of thesubstrate from side edge to side edge. A second conductive layer 23substantially covers the entirety of a second surface, e.g., the bottomside, of insulative base substrate 21. However, one or both of theconductive layers may terminate proximally of the distal edge and/or mayhave a width which is less than that of insulative substrate 21 wherethe width ends a selected distance from the side edges of the substrate,which distance may be equidistant or vary from each of the side edges.

One of the first or second conductive layers, e.g., first conductivelayer 22, may be configured to include the sensor's working electrode.The opposing conductive layer, here, second conductive layer 23, may beconfigured to include a reference and/or counter electrode. Whereconductive layer 23 serves as either a reference or counter electrode,but not both, a third electrode may optionally be provided either on asurface area of the proximal portion of the sensor (not shown), on aseparate substrate, or as an additional conductive layer positionedeither above or below conductive layer 22 or 23 and separated from thoselayers by an insulative layer or layers. For example, in someembodiments, where analyte sensor 20 is configured to be partiallyimplanted, conductive layer 23 may be configured to include a referenceelectrode and a third electrode (not shown) and present only on anon-implanted proximal portion of the sensor may be configured toinclude the sensor's counter electrode.

A first insulative layer 24 covers at least a portion of conductivelayer 22 and a second insulative layer 25 covers at least a portion ofconductive layer 23. In one embodiment, at least one of first insulativelayer 24 and second insulative layer 25 does not extend to the distalend of analyte sensor 20 leaving an exposed region of the conductivelayer or layers.

FIG. 3 shows a cross-sectional view of a distal portion of adouble-sided analyte sensor 30 including an at least generally planarinsulative base substrate 31, e.g., an at least generally planardielectric base substrate, having a first conductive layer 32 whichsubstantially covers the entirety of a first surface area, e.g., the topsurface area, of insulative substrate 31, i.e., the conductive layersubstantially extends the entire length of the substrate to the distaledge and across the entire width of the substrate from side edge to sideedge. A second conductive layer 33 substantially covers the entirety ofa second surface, e.g., the bottom side, of insulative base substrate31. However, one or both of the conductive layers may terminateproximally of the distal edge and/or may have a width which is less thanthat of insulative substrate 31 where the width ends a selected distancefrom the side edges of the substrate, which distance may be equidistantor vary from each of the side edges.

In the embodiment of FIG. 3, conductive layer 32 is configured toinclude a working electrode which includes a sensing component or layer32A disposed on at least a portion of the first conductive layer 32 asshown and as discussed in greater detail below. While a single sensingcomponent or layer 32A is shown, it should be noted that in otherembodiments a plurality of spatially separated sensing components orlayers may be utilized.

In the embodiment of FIG. 3, conductive layer 33 is configured toinclude a reference electrode which includes a secondary layer ofconductive material 33A, e.g., Ag/AgC1, disposed over a distal portionof conductive layer 33.

A first insulative layer 34 covers a portion of conductive layer 32 anda second insulative layer 35 covers a portion of conductive layer 33.First insulative layer 34 does not extend to the distal end of analytesensor 20 leaving an exposed region of the conductive layer where thesensing component or layer 32A is positioned. The insulative layer 35 onthe bottom/reference electrode side of the sensor, may extend anysuitable length of the sensor's distal section, i.e., it may extend theentire length of both of the primary and secondary conductive layers orportions thereof. For example, as illustrated in FIG. 3, bottominsulative layer 35 extends over the entire bottom surface area ofsecondary conductive material 33A but terminates proximally of thedistal end of the length of the conductive layer 33. It is noted that atleast the ends of the secondary conductive material 33A which extendalong the side edges of the substrate 31 are not covered by insulativelayer 35 and, as such, are exposed to the environment when in operativeuse.

In an alternative embodiment, as shown in FIG. 4, insulative layer 44 onthe working electrode side of an insulative base substrate 41 may beprovided prior to sensing layer 42A whereby the insulative layer 44 hasat least two portions spaced apart from each other on conductive layer42. The sensing material 42A is then provided in the spacing between thetwo portions. More than two spaced apart portions may be provided, e.g.,where a plurality of sensing components or layers is desired. Bottominsulative layer 45 has a length which terminates proximally ofsecondary conductive layer 43 a on bottom primary conductive layer 43.Additional conducting and dielectric layers may be provided on either orboth sides of the sensors, as described above.

While FIGS. 2-4 depict or are discussed herein as capable of providingthe working and reference electrodes in a particular layeredconfiguration, it should be noted that the relative positioning of theselayers may be modified. For example, a counter electrode layer may beprovided on one side of an insulative base substrate while working andreference electrode layers are provided in a stacked configuration onthe opposite side of the insulative base substrate. In addition, adifferent number of electrodes may be provided than depicted in FIGS.2-4 by adjusting the number of conductive and insulative layers. Forexample, a 3 or four electrode sensor may be provided.

One or more membranes, which may function as one or more of an analyteflux modulating layer and/or an interferent-eliminating layer and/orbiocompatible layer, discussed in greater detail below, may be providedabout the sensor, e.g., as one or more of the outermost layer(s). Incertain embodiments, as illustrated in FIG. 3, a first membrane layer 36may be provided solely over the sensing component or sensing layer 32Aon the working electrode 32 to modulate the rate of diffusion or flux ofthe analyte to the sensing layer. For embodiments in which a membranelayer is provided over a single component/material, it may be suitableto do so with the same striping configuration and method as used for theother materials/components. Here, the stripe/band of membrane material36 preferably has a width greater than that of sensing stripe/band 32A.As it acts to limit the flux of the analyte to the sensor's active area,and thus contributes to the sensitivity of the sensor, controlling thethickness of membrane 36 is important. Providing membrane 36 in the formof a stripe/band facilitates control of its thickness. A second membranelayer 37, which coats the remaining surface area of the sensor tail, mayalso be provided to serve as a biocompatible conformal coating andprovide smooth edges over the entirety of the sensor. In other sensorembodiments, as illustrated in FIG. 4, a single, homogenous membrane 46may be coated over the entire sensor surface area, or at least over bothsides of the distal tail portion. It is noted that to coat the distaland side edges of the sensor, the membrane material may have to beapplied subsequent to singulation of the sensor precursors. In someembodiments, the analyte sensor is dip-coated following singulation toapply one or more membranes. Alternatively, the analyte sensor could beslot-die coated wherein each side of the analyte sensor is coatedseparately.

FIG. 5 shows a cross-sectional view of a distal portion of adouble-sided analyte sensor 50 according to one embodiment of thepresent disclosure, wherein the double-sided analyte sensor includes anat least generally planar insulative base substrate 51, e.g., an atleast generally planar dielectric base substrate, having a firstconductive layer 52. A second conductive layer 53 is positioned on afirst side, e.g., the bottom side, of insulative base substrate 51.While depicted as extending to the distal edge of the sensor, one orboth of the conductive layers may terminate proximally of the distaledge and/or may have a width which is less than that of insulativesubstrate 51 where the width ends a selected distance from the sideedges of the substrate, which distance may be equidistant or vary fromeach of the side edges. See, for example, the analyte sensor assembly500, discussed in more detail below, wherein first and second conductivelayers are provided which define electrodes, including, e.g., electrodetraces, which have widths which are less than that of the insulativebase substrate.

In the embodiment of FIG. 5, conductive layer 53 is configured toinclude a working electrode which includes a sensing component or layer(not shown) disposed on at least a portion of the conductive layer 53,which sensing component or layer is discussed in greater detail below.It should be noted that a plurality of spatially separated sensingcomponents or layers may be utilized in forming the working electrode,e.g., one or more sensing “dots” or areas may be provided on theconductive layer 53.

In the embodiment of FIG. 5, conductive layer 56 is configured toinclude a reference electrode which includes a secondary layer ofconductive material 56A, e.g., Ag/AgC1, disposed on a distal portion ofconductive layer 56. Like conductive layers 52 and 53, conductive layer56 may terminate proximally of the distal edge and/or may have a widthwhich is less than that of insulative substrate 51 where the width endsa selected distance from the side edges of the substrate, which distancemay be equidistant or vary from each of the side edges.

In the embodiment shown in FIG. 5, conductive layer 52 is configured toinclude a counter electrode. A first insulative layer 54 covers aportion of conductive layer 52 and a second insulative layer 55 covers aportion of conductive layer 53. First insulative layer 54 does notextend to the distal end of analyte sensor 50 leaving an exposed regionof the conductive layer 52 which acts as the counter electrode. Aninsulative layer 55 covers a portion of conductive layer 53 leaving anexposed region of the conductive layer 53 where the sensing component orlayer (not shown) is positioned. As discussed above, multiple spatiallyseparated sensing components or layers may be provided in someembodiments. The insulative layer 57 on a first side, e.g., the bottomside of the sensor (in the view provided by FIG. 5), may extend anysuitable length of the sensor's distal section, i.e., it may extend theentire length of both of conductive layers 56 and 56A or portionsthereof. For example, as illustrated in FIG. 5, bottom insulative layer57 extends over the entire bottom surface area of secondary conductivematerial 56A and terminates distally of the distal end of the length ofthe conductive layer 56. It is noted that at least the ends of thesecondary conductive material 56A which extend along the side edges ofthe substrate 51 are not covered by insulative layer 57 and, as such,are exposed to the environment when in operative use.

As discussed previously herein, when manufacturing layered sensors, itmay be desirable to utilize relatively thin insulative layers to reducetotal sensor width. For example, with reference to FIG. 5, insulativelayers 54, 55 and 57 may be relatively thin relative to insulativesubstrate layer 51. For example, insulative layers 54, 55 and 57 mayhave a thickness in the range of 20-25 μm while substrate layer 51 has athickness in the range of 0.1 to 0.15 mm. However, during singulation ofthe sensors where such singulation is accomplished by cutting throughtwo or more conductive layers which are separated by such thininsulative layers, shorting between the two conductive layers may occur.One method of addressing this potential issue is to provide one of theconductive layers, e.g., electrodes layers, at least in part as arelatively narrow electrode, including, e.g., a relatively narrowconductive trace, such that during the singulation process the sensor iscut on either side of the narrow electrode such that one electrode iscut without cutting through the narrow electrode. See, for example,sensor assembly 500 depicted in FIG. 6 in which working electrode 502 isprovided at its distal end as a relatively thin electrode relative toreference electrode 504. In addition, one of the conductive layers maybe spaced back from the other conductive layer at the distal end of thesensor. One of the sensors may extend, for example, to the distal tip ofthe sensor while the other terminates proximal to the distal tip of thesensor. In this manner, the sensor may be cut perpendicularly to thelength of the sensor and across one of the conductive layers withoutcutting through two conductive layers separated by only a thininsulative layer, e.g., an insulative layer having a thickness fromabout 15 to 30 μm. In the embodiment depicted in FIG. 5 the referenceelectrode 56 is spaced back distally relative to the working electrode53. However, this positioning could be reversed.

As discussed above, the use of a sensor connector, e.g., a rivet, as amechanism for attachment of an analyte sensor to an electronics unit,such as sensor control unit, e.g., to a PCB of the sensor control unit,may result in improved attachment of the analyte sensor to the sensorcontrol unit as compared with other attachment methods, e.g., the use ofone or more adhesives. The sensor connector, e.g., a rivet, may be madefrom a variety of suitable materials depending on the particularembodiment. For example, in some embodiments, the sensor connector,e.g., a rivet, physically connects the double-sided analyte sensor andthe electronics unit. In other embodiments, the sensor connector, e.g.,rivet physically and electrically connects the double-sided analytesensor and the electronics unit. Where the sensor connector, e.g., rivetphysically connects the analyte sensor and the electronics unit, thesensor connector, e.g., rivet may be made from any suitable conductiveor non-conductive material. Where the sensor connector, e.g., rivetphysically and electrically connects the double-sided analyte sensor andthe electronics unit, the sensor connector, e.g., rivet, may be madefrom any suitable conductive material, e.g., copper. In one suchembodiment, the sensor connector, e.g., rivet, may conduct an electricalsignal from an electrode, including, e.g., a conductive trace,positioned on one side of the double-sided analyte sensor to the otherside of the double-sided analyte sensor, e.g., for electrical connectionwith a PCB to which the double-sided analyte sensor is attached. In thisway, both sides of a double-sided analyte sensor may be electricallyconnected to the sensor control unit. Where a plurality of electrodes ispresent, one or more of the plurality of electrodes may be electricallyconnected to the PCB via a corresponding conductive sensor connector,e.g., a conductive rivet. For example, an analyte sensor having threeelectrodes may include 1, 2 or 3 conductive sensor connectors, e.g.,conductive rivets; an analyte sensor having four electrodes may include1, 2, 3 or 4 conductive sensor connectors, e.g., conductive rivets; etc.Additional non-conductive and conductive sensor connector, e.g., rivet,materials are discussed in greater detail above.

A double-sided analyte sensor may provide certain advantages over asingle-sided analyte sensor. Specifically, by positioning electrodes,e.g., including conductive traces, on both sides of a dielectric baselayer, a reduction in analyte sensor width can be achieved. For example,such a double-sided analyte sensor may have width of less than 0.5 mm,e.g., less than 0.3 mm. Additional descriptions of double-sided analytesensors can be found, for example, in U.S. Publication Nos. 2010/0230285and 2011/0021889, the disclosure of each of which is incorporated byreference herein in its entirety and for all purposes.

Exemplary embodiments of a double-sided analyte sensor for use inconnection with the disclosed devices, methods, systems and kits willnow be described in greater detail with reference to FIGS. 6-14 whichdepict an analyte sensor assembly showing the various layers of theanalyte sensor as they may be positioned in an analyte sensor sheetcontaining a plurality of analyte sensors prior to singulation of anindividual analyte sensor. FIG. 6 provides an exploded view of ananalyte sensor assembly 500 according to one embodiment of the presentdisclosure. Analyte sensor assembly 500 includes a Layer 0 in the formof a flexible insulative base substrate, e.g., a flexible dielectricsubstrate 501. The flexible dielectric substrate 501 may be made of anysuitable dielectric material having the desired flexibility. Forexample, the flexible dielectric substrate 501 may be a clear,high-gloss, heat stabilized polyester film. Other suitable materials areprovided below and still others may be readily identified by those ofordinary skill in the art.

Working electrode 502, including a working electrode trace, Layer 1, ispositioned on flexible dielectric substrate 501. See, FIGS. 6 and 8. Avariety of conductive materials may be used to form working electrode502, and many such materials are known to those of ordinary skill in theart. A discussion of suitable materials is also provided below. In oneembodiment, working electrode 502 is applied in the form of a carbonink. FIG. 8 also depicts electrical contacts 502B, 502C and 502D.Electrical contact 502B is configured to provide an electricalconnection with an electronics unit, such as sensor control unit, e.g.,a PCB of a sensor control unit. Optional electrical contacts 502C and502D may be utilized during the manufacturing process to test thefunctionality of the working electrode, and may be subsequently removedduring singulation of the analyte sensor or not provided at all.

A dielectric layer 503, Layer 2, is positioned to cover a portion ofworking electrode 502 as shown in FIGS. 6 and 9. In one embodiment, asuitable dielectric is a UV curable dielectric. Additional suitabledielectric materials are described below and others may be readilyidentified by those of ordinary skill in the art.

Reference electrode 504, Layer 3, is positioned on dielectric layer 503and flexible dielectric substrate 501 as shown in FIGS. 6 and 10. Avariety of conductive materials may be used to form reference electrode504, e.g., carbon ink, and many such materials are known to those ofordinary skill in the art. A discussion of suitable materials is alsoprovided below. In addition, reference electrode 504 includes a Ag/AgC1layer 505, Layer 3A, applied to a portion thereof as depicted in FIGS. 6and 11. Additional reference electrode materials known to those ofordinary skill in the art may be utilized in connection with the presentdisclosure. Also shown are electrical contacts 504A and 504B. Electricalcontact 504A is configured to provide an electrical connection with anelectronics unit, such as a sensor control unit, e.g., a PCB of a sensorcontrol unit. Optional electrical contact 504B may be utilized duringthe manufacturing process to test the functionality of the referenceelectrode, and may be subsequently removed during singulation of theanalyte sensor or not provided at all.

A dielectric layer 506, Layer 4, is positioned over (relative to theplane of the page in FIG. 12) the Ag/AgC1 layer and the working andreference electrode layers as shown in FIG. 12. As shown in FIG. 12,this layer may be applied in two separate parts, however, embodiments inwhich this dielectric layer is applied as a single part are alsocontemplated by the disclosure. In one embodiment, a suitable dielectricis a UV curable dielectric. Additional suitable dielectric materials aredescribed below and others may be readily identified by those ofordinary skill in the art.

A counter electrode 507, Layer 5, is positioned on flexible dielectricsubstrate 501 on the opposite side of flexible dielectric substrate 501as working electrode 502 as shown in FIG. 13. A variety of conductivematerials may be used to form counter electrode 507, and many suchmaterials are known to those of ordinary skill in the art. A discussionof suitable materials is also provided below. In one embodiment, counterelectrode 507 is applied in the form of a carbon ink. Also shown areelectrical contacts 507A and 507B. Electrical contact 507A is configuredto provide an electrical connection with an electronics unit, such as asensor control unit, e.g., a PCB of a sensor control unit. Optionalelectrical contact 507B may be utilized during the manufacturing processto test the functionality of the counter electrode, and may besubsequently removed during singulation of the analyte sensor.

An additional dielectric layer 508, Layer 6, is applied over portions ofcounter electrode 507 as shown in FIG. 14. In one embodiment, a suitabledielectric is a UV curable dielectric. Additional suitable dielectricmaterials are described below and others may be readily identified thoseof ordinary skill in the art.

FIG. 7 provides a top transparent view of the analyte sensor assembly500 in singulated form; a top view of the analyte sensor assembly 500 insingulated form showing the counter electrode 507; and a bottom view ofthe analyte sensor assembly 500 in singulated form showing the referenceelectrode 504 and working electrode 502. Dotted line 509 represents acut line at which the sensor assembly 500 may be cut to remove excessmaterial prior to or after attachment of the analyte sensor assembly 500to a sensor control unit. Conductive electrode traces to the right ofthe cut lines and their corresponding electrical contacts may be used totest the function of the analyte sensor assembly prior to and/or afterattachment of the sensor assembly to a sensor control unit. Theseconductive traces and associated dielectric layers may be removed priorto use of the analyte sensor assembly and an associated sensor controlunit, e.g., by cutting along cut line 509. Alternatively, an analytesensor assembly 500 may be prepared which does not include electrodetraces which extend at their proximal end beyond, e.g., the positionindicated by cut line 509. In still another embodiment, the variouselectrode traces are formed to terminate at their proximal ends atelectrode contacts 502B, 504A and 507A.

In some embodiments, an analyte sensor according to the presentdisclosure may include an optional identifier, which uniquely identifiesat least one of the analyte sensors, the batch or lot of analyte sensorsfrom which the analyte sensor originated, and/or combinations thereof.The identifier may include, e.g., an alphanumeric identifier, one ormore symbols, bar codes, etc. In some embodiments, the identifierprovides information identifying the location, e.g., row and column, ofthe analyte sensor on a sheet containing a plurality of analyte sensorsprior to singulation. The identifier may in some embodiments be madefrom the same conductive material as one or more of the conductivelayers of the analyte sensor and may, in some embodiments, be applied orformed in the same manner as one or more of the conductive layers of theanalyte sensor, via a printing or ablation method. In some embodiments,the identifier may be provided by removing material from one or more ofthe insulative layers of the analyte sensor to provide an identifyingpattern, e.g., a bar code, and/or an alphanumeric identifier. Forexample, the identifier may be etched, cut, or ablated into one or moreof the insulative layers of the analyte sensor, e.g., the insulativebase substrate. In some embodiments, an identifier as described above isused, e.g., during the manufacturing process, to identify a sheet ofanalyte sensors prior to singulation. In such embodiments, theindividual sensors may or may not include an identifier aftersingulation.

Exemplary embodiments of a double-sided analyte sensor with a sensorconnector, e.g., rivet, attachment to a sensor control unit is nowdescribed with reference to FIGS. 16A and 16B, which shows a generalizedsensor connector concept according to one embodiment of the presentdisclosure. As shown in FIGS. 16A and 16B, a sensor connector, e.g., arivet 600, makes contact with an electrical contact 701 (full electrodetrace not shown) on a first side, e.g., the top side, of a planar,double-sided analyte sensor 700. The rivet mechanically couples theanalyte sensor 700 to a PCB 800 of a sensor control unit therebyproviding contact between electrical contacts 702-704 (full electrodetraces not shown) on a second side, e.g., the bottom, of the analytesensor 700 and electrical contacts 801-803 and on a first side, e.g.,the top, of the PCB 800. By forming the rivet, e.g., by using a spiralforming, impact forming or orbit forming method, contact between therivet 600 and an electrical contact 804 on a second side, e.g., thebottom of the PCB 800 is provided which in turn provides an electricalconnection between the electrical contact 701 on a first side, e.g.,top, of the analyte sensor and the electrical contact 804 on the secondside, e.g., bottom, of the PCB 800. In the embodiment shown in FIGS. 16Aand 16B, electrical contact 804 includes an electrical trace 804A whichextends through PCB 800. In this way, electrical signals to or from eachof electrical contacts 702-704 and 701 may be communicated to or fromthe same side of PCB 800. While FIGS. 16A and 16B indicate an analytesensor having a four electrode system, one of skill in the art willreadily understand that this embodiment may be adjusted to accommodateanalyte sensors having any of a variety of electrode configurations. Forexample, the embodiment of FIGS. 16A and 16B could be adjusted toaccommodate a three electrode analyte sensor such as the one describedwith reference to FIGS. 6-14 above. Similarly, while FIGS. 16A and 16Bdepict a conductive rivet sensor connector, the embodiment may beadapted to accommodate other conductive connectors as described hereinor known in the art.

Stacked Sensor Having First Electrode Narrower than Second Electrode

When manufacturing analyte sensors having at least two electrodes thatare stacked, i.e., layered, or sensors which include a stacked electrodeconfiguration, relatively thin insulative layers may be used, e.g.,insulative layers having a thickness of about 15 μm to about 150 μm,e.g., about 15 μm to about 100 μm, about 15 μm to about 50 μm, about 15μm to about 40 μm, about 15 μm to about 30 μm, about 15 μm to about 25μm, or about 20 μm, to reduce the cross-sectional area of the sensor ora portion thereof. This may be desirable, for example, where the analytesensor is completely body-implanted or partially body-implanted. Byreducing the cross-sectional area of the analyte sensor, an analytesensor is produced which can be inserted while causing less pain and/ordiscomfort to the user.

For example, with reference to FIGS. 1A-1D, a sensor 10 is providedwhich includes insulative layers 13 and 15. Insulative layers 13 and 15may be thin relative to generally planar insulative base substrate layer11, or vice versa. For example, insulative layers 13 and 15 may have athickness in the range of 15-30 μm while substrate layer 11 has athickness in the range of 0.1 to 0.15 mm. Such sensors may bemanufactured in sheets wherein a single sheet includes a plurality ofsensors. However, such a process generally requires singulation of thesensors prior to use. Where such singulation requires cutting throughtwo or more conductive layers which are separated by insulative layers,shorting between the two conductive layers may occur, particularly ifthe insulative layers are thin. In order to avoid such shorting, fewerthan all of the conductive layers may be cut through during thesingulation process. For example, at least one of the conductive layersmay be provided at least in part as an electrode, e.g., including aconductive trace, having a narrow width relative to one or more otherconductive layers such that during the singulation process a firstconductive layer separated from a second conductive layer only by a thininsulative layer, e.g., an insulative layer having a thickness in therange of 15-30 μm, is cut while a second conductive layer is not.

For example, with reference to FIGS. 1A and 1C, a sensor 10 includes anat least generally planar insulative base substrate 11. Positioned onthe at least generally planar insulative base substrate 11 is a firstconductive layer 12. A first relatively thin insulative layer 13, e.g.,an insulative layer having a thickness in the range of 15-30 μm, ispositioned on the first conductive layer 12 and second conductive layer14 is positioned on the relatively thin insulative layer 13. Finally, asecond relatively thin insulative layer 15, e.g., an insulative layerhaving a thickness in the range of 15-30 μm, is positioned on the secondconductive layer 14. As shown in FIG. 1B, first conductive layer 12 maybe a an electrode having a narrow width relative to conductive layer 14as shown in the FIG. 1B cross-section taken at lines A-A. Alternatively,second conductive layer 14 may be a conductive electrode having a narrowwidth relative to conductive layer 12 as shown in the FIG. 1Ccross-section taken at lines A-A. Singulation cut lines 16 are shown inFIGS. 1B, 1C and 1D. The sensor may be singulated, for example, bycutting to either side of the relatively narrow conductive electrode,e.g., in regions 17, as shown in FIGS. 1B, 1C and 1D. With reference toFIGS. 1B and 1D, singulation by cutting along singulation cut lines 16results in cutting through conductive layer 14 but not conductive layer12. With reference to FIG. 1C, singulation by cutting along singulationcut lines 16 results in cutting through conductive layer 12 but notconductive layer 14.

FIG. 1D shows an embodiment of the sensor shown in FIG. 1B as it may beprovided prior to singulation during the manufacturing process. Itshould be noted that while FIGS. 1B and 1C appear to depict empty spaceto either side of conductive layers 12 and 14 respectively, one ofordinary skill in the art will understand that insulative layers 13and/or 15, may extend into these spaces thereby covering side edges ofconductive layer 12 and 14 respectively.

In an embodiment, first conductive layer 12 is an electrode having arelatively narrow width relative to conductive layer 14 and is a workingelectrode while conductive layer 14 is a reference electrode orcounter/reference electrode. In another embodiment, second conductivelayer 14 is an electrode having a relatively narrow width relative toconductive layer 12 and is a working electrode while conductive layer 12is a reference electrode or counter/reference electrode.

In addition, one of the conductive layers may be spaced back from theother conductive layer at the distal end of the sensor, e.g., thesensing end of the sensor. One of the conductive layers may extend, forexample, to the distal tip of the sensor while the other terminatesproximal to the distal tip of the sensor. In this manner, the sensor maybe cut perpendicularly to the length of the sensor and across one of theconductive layers without cutting through two conductive layersseparated by only a thin insulative layer e.g., an insulative layerhaving a thickness in the range of 15-30 μm. In the embodiment depictedin FIG. 1A the second conductive layer 14 is spaced back distallyrelative to the first conductive layer 12. While FIGS. 1A-1D depict atwo electrode sensor, it should be noted that this sensor structure maybe readily modified to accommodate additional electrode layers, e.g., inthe case of sensors having 3 or 4 electrodes.

Electrochemical Sensors

Embodiments of the present disclosure relate to methods and devices fordetecting at least one analyte, including glucose, in body fluid.Embodiments relate to the continuous and/or automatic in vivo monitoringof the level of one or more analytes using a continuous analytemonitoring system that includes an analyte sensor at least a portion ofwhich is to be positioned beneath a skin surface of a user for a periodof time and/or the discrete monitoring of one or more analytes using anin vitro blood glucose (“BG”) meter and an analyte test strip.Embodiments include combined or combinable devices, systems and methodsand/or transferring data between an in vivo continuous system and an invitro system. In some embodiments, the systems, or at least a portion ofthe systems, are integrated into a single unit.

A sensor as described herein may be an in vivo sensor or an in vitrosensor (e.g., a discrete monitoring test strip). In certain embodiments,the sensor is a single-sided analyte sensor as described herein. Inother embodiments, the sensor is a double-sided analyte sensor asdescribed herein.

Embodiments of the present disclosure include analyte monitoring devicesand systems that include an analyte sensor, at least a portion of whichis positionable beneath the skin surface of the user for the in vivodetection of an analyte, including glucose, lactate, and the like, in abody fluid. Embodiments include wholly implantable analyte sensors andanalyte sensors in which only a portion of the sensor is positionedunder the skin and a portion of the sensor resides above the skin, e.g.,for contact to an electronics unit, such as a sensor control unit (whichmay include a transmitter), a receiver/display unit, transceiver,processor, etc. The sensor may be, for example, subcutaneouslypositionable in a user for the continuous or periodic monitoring of alevel of an analyte in the user's interstitial fluid. For the purposesof this description, continuous monitoring and periodic monitoring willbe used interchangeably, unless noted otherwise and are intended toinclude both continuous and on-demand analyte measurement systems knownin the art. The sensor response may be correlated and/or converted toanalyte levels in blood or other fluids. In certain embodiments, ananalyte sensor may be positioned in contact with interstitial fluid todetect the level of glucose, which detected glucose may be used to inferthe glucose level in the user's bloodstream. Analyte sensors may beinsertable into a vein, artery, or other portion of the body containingfluid. Embodiments of the analyte sensors may be configured formonitoring the level of the analyte over a time period which may rangefrom seconds, minutes, hours, days, weeks, to months, or longer.

In certain embodiments, the analyte sensors, such as glucose sensors,are capable of in vivo detection of an analyte for one hour or more,e.g., a few hours or more, e.g., a few days or more, e.g., three or moredays, e.g., five days or more, e.g., seven days or more such as fourteendays or more, e.g., several weeks or more such as 3 weeks or more, orone month or more. Future analyte levels may be predicted based oninformation obtained, e.g., the current analyte level at time t₀, therate of change of the analyte, etc. Predictive alarms may notify theuser of a predicted analyte level that may be of concern in advance ofthe user's analyte level reaching the future predicted analyte level.This provides the user an opportunity to take corrective action.

Analytes that may be monitored include, but are not limited to, acetylcholine, amylase, bilirubin, cholesterol, chorionic gonadotropin,glycosylated hemoglobin (HbA Ic), creatine kinase (e.g., CK-MB),creatine, creatinine, DNA, fructosamine, glucose, glucose derivatives,glutamine, growth hormones, hormones, ketones, ketone bodies, lactate,peroxide, prostate-specific antigen, prothrombin, RNA, thyroidstimulating hormone, and troponin. The concentration of drugs, such as,for example, antibiotics (e.g., gentamicin, vancomycin, and the like),digitoxin, digoxin, drugs of abuse, theophylline, and warfarin, may alsobe monitored. In embodiments that monitor more than one analyte, theanalytes may be monitored at the same or different times.

Analyte sensors may include an analyte-responsive enzyme to provide asensing element. Some analytes, such as oxygen, can be directlyelectrooxidized or electroreduced on a sensor, and more specifically atleast on a working electrode of a sensor. Other analytes, such asglucose and lactate, require the presence of at least one electrontransfer agent and/or at least one catalyst to facilitate theelectrooxidation or electroreduction of the analyte. Catalysts may alsobe used for those analytes, such as oxygen, that can be directlyelectrooxidized or electroreduced on the working electrode. For theseanalytes, each working electrode includes a sensing element proximate toor on a surface of a working electrode. In many embodiments, a sensingelement is formed near or on only a small portion of at least a workingelectrode.

Each sensing element includes one or more components constructed tofacilitate the electrochemical oxidation or reduction of the analyte.The sensing element may include, for example, a catalyst to catalyze areaction of the analyte and produce a response at the working electrode,an electron transfer agent to transfer electrons between the analyte andthe working electrode (or other component), or both.

A variety of different sensing element configurations may be used. Incertain embodiments, the sensing elements are deposited on theconductive material of a working electrode. The sensing elements mayextend beyond the conductive material of the working electrode. In somecases, the sensing elements may also extend over other electrodes, e.g.,over the counter electrode and/or reference electrode (orcounter/reference where provided). In other embodiments, the sensingelements are contained on the working electrode, such that the sensingelements do not extend beyond the conductive material of the workingelectrode. In some embodiments a working electrode is configured toinclude a plurality of spatially distinct sensing elements. Additionalinformation related to the use of spatially distinct sensing elementscan be found in U.S. Provisional Application No. 61/421,371, entitled“Analyte Sensors with Reduced Sensitivity Variation,” which was filed onDec. 9, 2010, and which is incorporated by reference herein in itsentirety and for all purposes.

The terms “working electrode”, “counter electrode”, “referenceelectrode” and “counter/reference electrode” are used herein to refer toconductive sensor components, including, e.g., conductive traces, whichare configured to function as a working electrode, counter electrode,reference electrode or a counter/reference electrode respectively. Forexample, a working electrode includes that portion of a conductivematerial, e.g., a conductive trace, which functions as a workingelectrode as described herein, e.g., that portion of a conductivematerial which is exposed to an environment containing the analyte oranlaytes to be measured, and which, in some cases, has been modifiedwith one or more sensing elements as described herein Similarly, areference electrode includes that portion of a conductive material,e.g., conductive trace, which function as a reference electrode asdescribed herein, e.g., that portion of a conductive material which isexposed to an environment containing the analyte or anlaytes to bemeasured, and which, in some cases, includes a secondary conductivelayer, e.g., a Ag/AgC1 layer. A counter electrode includes that portionof a conductive material, e.g., conductive trace which is configured tofunction as a counter electrode as described herein, e.g., that portionof a conductive trace which is exposed to an environment containing theanalyte or anlaytes to be measured. As noted above, in some embodiments,a portion of a conductive material, e.g., conductive trace, may functionas either or both of a counter electrode and a reference electrode. Inaddition, “working electrodes”, “counter electrodes”, “referenceelectrodes” and “counter/reference electrodes” may include portions,e.g., conductive traces, electrical contacts, or areas or portionsthereof, which do not include sensing elements but which are used toelectrically connect the electrodes to other electrical components.

Sensing elements that are in direct contact with the working electrode,e.g, the working electrode trace, may contain an electron transfer agentto transfer electrons directly or indirectly between the analyte and theworking electrode, and/or a catalyst to facilitate a reaction of theanalyte. For example, a glucose, lactate, or oxygen electrode may beformed having sensing elements which contain a catalyst, includingglucose oxidase, glucose dehydrogenase, lactate oxidase, or laccase,respectively, and an electron transfer agent that facilitates theelectrooxidation of the glucose, lactate, or oxygen, respectively.

In other embodiments the sensing elements are not deposited directly onthe working electrode, e.g, the working electrode trace. Instead, thesensing elements may be spaced apart from the working electrode trace,and separated from the working electrode trace, e.g., by a separationlayer. A separation layer may include one or more membranes or films ora physical distance. In addition to separating the working electrodetrace from the sensing elements, the separation layer may also act as amass transport limiting layer and/or an interferent eliminating layerand/or a biocompatible layer.

In certain embodiments which include more than one working electrode,one or more of the working electrodes may not have corresponding sensingelements, or may have sensing elements that do not contain one or morecomponents (e.g., an electron transfer agent and/or catalyst) needed toelectrolyze the analyte. Thus, the signal at this working electrode maycorrespond to background signal which may be removed from the analytesignal obtained from one or more other working electrodes that areassociated with fully-functional sensing elements by, for example,subtracting the signal.

In certain embodiments, the sensing elements include one or moreelectron transfer agents. Electron transfer agents that may be employedare electroreducible and electrooxidizable ions or molecules havingredox potentials that are a few hundred millivolts above or below theredox potential of the standard calomel electrode (SCE). The electrontransfer agent may be organic, organometallic, or inorganic. Examples oforganic redox species are quinones and species that in their oxidizedstate have quinoid structures, such as Nile blue and indophenol.Examples of organometallic redox species are metallocenes includingferrocene. Examples of inorganic redox species are hexacyanoferrate(III), ruthenium hexamine, etc. Additional examples include thosedescribed in U.S. Pat. Nos. 6,736,957, 7,501,053 and 7,754,093, thedisclosures of each of which are incorporated herein by reference intheir entirety.

In certain embodiments, electron transfer agents have structures orcharges which prevent or substantially reduce the diffusional loss ofthe electron transfer agent during the period of time that the sample isbeing analyzed. For example, electron transfer agents include but arenot limited to a redox species, e.g., bound to a polymer which can inturn be disposed on or near the working electrode. The bond between theredox species and the polymer may be covalent, coordinative, or ionic.Although any organic, organometallic or inorganic redox species may bebound to a polymer and used as an electron transfer agent, in certainembodiments the redox species is a transition metal compound or complex,e.g., osmium, ruthenium, iron, and cobalt compounds or complexes. Itwill be recognized that many redox species described for use with apolymeric component may also be used, without a polymeric component.

Embodiments of polymeric electron transfer agents may contain a redoxspecies covalently bound in a polymeric composition. An example of thistype of mediator is poly(vinylferrocene). Another type of electrontransfer agent contains an ionically-bound redox species. This type ofmediator may include a charged polymer coupled to an oppositely chargedredox species. Examples of this type of mediator include a negativelycharged polymer coupled to a positively charged redox species such as anosmium or ruthenium polypyridyl cation. Another example of anionically-bound mediator is a positively charged polymer includingquaternized poly(4-vinyl pyridine) or poly(l-vinyl imidazole) coupled toa negatively charged redox species such as ferricyanide or ferrocyanide.In other embodiments, electron transfer agents include a redox speciescoordinatively bound to a polymer. For example, the mediator may beformed by coordination of an osmium or cobalt 2,2′-bipyridyl complex topoly(l-vinyl imidazole) or poly(4-vinyl pyridine).

Suitable electron transfer agents are osmium transition metal complexeswith one or more ligands, each ligand having a nitrogen-containingheterocycle such as 2,2′-bipyridine, 1,10-phenanthroline, 1-methyl,2-pyridyl biimidazole, or derivatives thereof. The electron transferagents may also have one or more ligands covalently bound in a polymer,each ligand having at least one nitrogen-containing heterocycle, such aspyridine, imidazole, or derivatives thereof. One example of an electrontransfer agent includes (a) a polymer or copolymer having pyridine orimidazole functional groups and (b) osmium cations complexed with twoligands, each ligand containing 2,2′-bipyridine, 1,10-phenanthroline, orderivatives thereof, the two ligands not necessarily being the same.Some derivatives of 2,2′-bipyridine for complexation with the osmiumcation include but are not limited to 4,4′-dimethyl-2,2′-bipyridine andmono-, di-, and polyalkoxy-2,2′-bipyridines, including4,4′-dimethoxy-2,2′-bipyridine. Derivatives of 1,10-phenanthroline forcomplexation with the osmium cation include but are not limited to4,7-dimethyl-1,10-phenanthroline and mono, di-, andpolyalkoxy-1,10-phenanthrolines, such as4,7-dimethoxy-1,10-phenanthroline. Polymers for complexation with theosmium cation include but are not limited to polymers and copolymers ofpoly(l-vinyl imidazole) (referred to as “PVI”) and poly(4-vinylpyridine) (referred to as “PVP”). Suitable copolymer substituents ofpoly(l-vinyl imidazole) include acrylonitrile, acrylamide, andsubstituted or quaternized N-vinyl imidazole, e.g., electron transferagents with osmium complexed to a polymer or copolymer of poly(l-vinylimidazole).

Embodiments may employ electron transfer agents having a redox potentialranging from about −200 mV to about +200 mV versus the standard calomelelectrode (SCE). The sensing elements may also include a catalyst whichis capable of catalyzing a reaction of the analyte. The catalyst mayalso, in some embodiments, act as an electron transfer agent. Oneexample of a suitable catalyst is an enzyme which catalyzes a reactionof the analyte. For example, a catalyst, including a glucose oxidase,glucose dehydrogenase (e.g., pyrroloquinoline quinone (PQQ), dependentglucose dehydrogenase, flavine adenine dinucleotide (FAD) dependentglucose dehydrogenase, or nicotinamide adenine dinucleotide (NAD)dependent glucose dehydrogenase), may be used when the analyte ofinterest is glucose. A lactate oxidase or lactate dehydrogenase may beused when the analyte of interest is lactate. Laccase may be used whenthe analyte of interest is oxygen or when oxygen is generated orconsumed in response to a reaction of the analyte.

In certain embodiments, a catalyst may be attached to a polymer, crosslinking the catalyst with another electron transfer agent, which, asdescribed above, may be polymeric. A second catalyst may also be used incertain embodiments. This second catalyst may be used to catalyze areaction of a product compound resulting from the catalyzed reaction ofthe analyte. The second catalyst may operate with an electron transferagent to electrolyze the product compound to generate a signal at theworking electrode. Alternatively, a second catalyst may be provided inan interferent-eliminating layer to catalyze reactions that removeinterferents.

In certain embodiments, the sensor works at a low oxidizing potential,e.g., a potential of about +40 mV vs. Ag/AgC1. This sensing elementsuse, for example, an osmium (Os)-based mediator constructed for lowpotential operation. Accordingly, in certain embodiments the sensingelements are redox active components that include: (1) osmium-basedmediator molecules that include (bidente) ligands, and (2) glucoseoxidase enzyme molecules. These two constituents are combined togetherin the sensing elements of the sensor.

A mass transport limiting layer (not shown), e.g., an analyte fluxmodulating layer, may be included with the sensor to act as adiffusion-limiting barrier to reduce the rate of mass transport of theanalyte, for example, glucose or lactate, into the region around theworking electrodes. The mass transport limiting layers are useful inlimiting the flux of an analyte to a working electrode in anelectrochemical sensor so that the sensor is linearly responsive over alarge range of analyte concentrations and is easily calibrated. Masstransport limiting layers may include polymers and may be biocompatible.A mass transport limiting layer may provide many functions, e.g.,biocompatibility and/or interferent-eliminating functions, etc.

A mass transport limiting layer may be applied to an analyte sensor asdescribed herein via any of a variety of suitable methods, including,e.g., dip coating and slot die coating.

In certain embodiments, a mass transport limiting layer is a membranecomposed of crosslinked polymers containing heterocyclic nitrogengroups, such as polymers of polyvinylpyridine and polyvinylimidazole.Embodiments also include membranes that are made of a polyurethane, orpolyether urethane, or chemically related material, or membranes thatare made of silicone, and the like.

A membrane may be formed by crosslinking in situ a polymer, modifiedwith a zwitterionic moiety, a non-pyridine copolymer component, andoptionally another moiety that is either hydrophilic or hydrophobic,and/or has other desirable properties, in an alcohol-buffer solution.The modified polymer may be made from a precursor polymer containingheterocyclic nitrogen groups. For example, a precursor polymer may bepolyvinylpyridine or polyvinylimidazole. Optionally, hydrophilic orhydrophobic modifiers may be used to “fine-tune” the permeability of theresulting membrane to an analyte of interest. Optional hydrophilicmodifiers, such as poly(ethylene glycol), hydroxyl or polyhydroxylmodifiers, may be used to enhance the biocompatibility of the polymer orthe resulting membrane.

A membrane may be formed in situ by applying an alcohol-buffer solutionof a crosslinker and a modified polymer over the enzyme-containingsensing elements and allowing the solution to cure for about one to twodays or other appropriate time period. The crosslinker-polymer solutionmay be applied over the sensing elements by placing a droplet ordroplets of the membrane solution on the sensor, by dipping the sensorinto the membrane solution, by spraying the membrane solution on thesensor, and the like. Generally, the thickness of the membrane iscontrolled by the concentration of the membrane solution, by the numberof droplets of the membrane solution applied, by the number of times thesensor is dipped in the membrane solution, by the volume of membranesolution sprayed on the sensor, or by any combination of these factors.In order to coat the distal and side edges of the sensor, the membranematerial may have to be applied subsequent to singulation of the sensorprecursors. In some embodiments, the analyte sensor is dip-coatedfollowing singulation to apply one or more membranes. Alternatively, theanalyte sensor could be slot-die coated wherein each side of the analytesensor is coated separately. A membrane applied in the above manner mayhave any combination of the following functions: (1) mass transportlimitation, i.e., reduction of the flux of analyte that can reach thesensing elements, (2) biocompatibility enhancement, or (3) interferentreduction.

In some embodiments, a membrane composition for use as a mass transportlimiting layer may include one or more leveling agents, e.g.,polydimethylsiloxane (PDMS). Additional information with respect to theuse of leveling agents can be found, for example, in U.S. PatentApplication Publication No. U.S. 2010/0081905, the disclosure of whichis incorporated by reference herein in its entirety.

In some instances, the membrane may form one or more bonds with thesensing elements. By bonds is meant any type of an interaction betweenatoms or molecules that allows chemical compounds to form associationswith each other, such as, but not limited to, covalent bonds, ionicbonds, dipole-dipole interactions, hydrogen bonds, London dispersionforces, and the like. For example, in situ polymerization of themembrane can form crosslinks between the polymers of the membrane andthe polymers in the sensing elements. In certain embodiments,crosslinking of the membrane to the sensing element facilitates areduction in the occurrence of delamination of the membrane from thesensor.

In certain embodiments, the sensing system detects hydrogen peroxide toinfer glucose levels. For example, a hydrogen peroxide-detecting sensormay be constructed in which the sensing elements include an enzyme suchas glucose oxidase, glucose dehydrogenase, or the like, and ispositioned on the working electrode. The sensing elements may be coveredby one or more layers, e.g., a membrane that is selectively permeable toglucose. Once the glucose passes through the membrane, it is oxidized bythe enzyme and reduced glucose oxidase can then be oxidized by reactingwith molecular oxygen to produce hydrogen peroxide.

Certain embodiments include a hydrogen peroxide-detecting sensorconstructed from sensing elements prepared by combining together, forexample: (1) a redox mediator having a transition metal complexincluding an Os polypyridyl complex with oxidation potentials of about+200 mV vs. SCE, and (2) periodate oxidized horseradish peroxidase(HRP). Such a sensor functions in a reductive mode; the workingelectrode is controlled at a potential negative to that of the Oscomplex, resulting in mediated reduction of hydrogen peroxide throughthe HRP catalyst.

In another example, a potentiometric sensor can be constructed asfollows. Glucose-sensing elements may be constructed by combiningtogether (1) a redox mediator having a transition metal complexincluding Os polypyridyl complexes with oxidation potentials from about−200 mV to +200 mV vs. SCE, and (2) glucose oxidase. This sensor canthen be used in a potentiometric mode, by exposing the sensor to aglucose containing solution, under conditions of zero current flow, andallowing the ratio of reduced/oxidized Os to reach an equilibrium value.The reduced/oxidized Os ratio varies in a reproducible way with theglucose concentration, and will cause the electrode's potential to varyin a similar way.

The substrate may be formed using a variety of non-conducting materials,including, for example, polymeric or plastic materials and ceramicmaterials. Suitable materials for a particular sensor may be determined,at least in part, based on the desired use of the sensor and propertiesof the materials.

In some embodiments, the substrate is flexible. For example, if thesensor is configured for implantation into a user, then the sensor maybe made flexible (although rigid sensors may also be used forimplantable sensors) to reduce pain to the user and damage to the tissuecaused by the implantation of and/or the wearing of the sensor. Aflexible substrate often increases the user's comfort and allows a widerrange of activities. Suitable materials for a flexible substrateinclude, for example, non-conducting plastic or polymeric materials andother non-conducting, flexible, deformable materials. Examples of usefulplastic or polymeric materials include thermoplastics such aspolycarbonates, polyesters (e.g., Mylar™ and polyethylene terephthalate(PET)), polyvinyl chloride (PVC), polyurethanes, polyethers, polyamides,polyimides, or copolymers of these thermoplastics, such as PETG(glycol-modified polyethylene terephthalate).

In other embodiments, the sensors are made using a relatively rigidsubstrate to, for example, provide structural support against bending orbreaking. Examples of rigid materials that may be used as the substrateinclude poorly conducting ceramics, such as aluminum oxide and silicondioxide. An implantable sensor having a rigid substrate may have a sharppoint and/or a sharp edge to aid in implantation of a sensor without anadditional insertion device.

It will be appreciated that for many sensors and sensor applications,both rigid and flexible sensors will operate adequately. The flexibilityof the sensor may also be controlled and varied along a continuum bychanging, for example, the composition and/or thickness of thesubstrate.

In addition to considerations regarding flexibility, it is oftendesirable that implantable sensors should have a substrate which isphysiologically harmless, for example, a substrate approved by aregulatory agency or private institution for in vivo use.

The sensor may include optional features to facilitate insertion of animplantable sensor. For example, the sensor may be pointed at the tip toease insertion. In addition, the sensor may include a barb which assistsin anchoring the sensor within the tissue of the user during operationof the sensor. However, the barb is typically small enough so thatlittle damage is caused to the subcutaneous tissue when the sensor isremoved for replacement.

An implantable sensor may also, optionally, have an anticlotting agentdisposed on a portion of the substrate which is implanted into a user.This anticlotting agent may reduce or eliminate the clotting of blood orother body fluid around the sensor, particularly after insertion of thesensor. Blood clots may foul the sensor or irreproducibly reduce theamount of analyte which diffuses into the sensor. Examples of usefulanticlotting agents include heparin and tissue plasminogen activator(TPA), as well as other known anticlotting agents.

The anticlotting agent may be applied to at least a portion of that partof the sensor that is to be implanted. The anticlotting agent may beapplied, for example, by bath, spraying, brushing, or dipping, etc. Theanticlotting agent is allowed to dry on the sensor. The anticlottingagent may be immobilized on the surface of the sensor or it may beallowed to diffuse away from the sensor surface. The quantities ofanticlotting agent disposed on the sensor may be below the amountstypically used for treatment of medical conditions involving blood clotsand, therefore, have only a limited, localized effect.

FIG. 17 schematically shows an analyte sensor 400 in accordance with oneembodiment of the present disclosure. This sensor embodiment includeselectrodes 401, 402 and 403 on a base 404. Electrodes (and/or otherfeatures) may be applied or otherwise processed using any suitabletechnology, e.g., chemical vapor deposition (CVD), physical vapordeposition, sputtering, reactive sputtering, printing, coating, ablating(e.g., laser ablation), painting, dip coating, etching, and the like.Materials include, but are not limited to, any one or more of aluminum,carbon (including graphite), cobalt, copper, gallium, gold, indium,iridium, iron, lead, magnesium, mercury (as an amalgam), nickel,niobium, osmium, palladium, platinum, rhenium, rhodium, selenium,silicon (e.g., doped polycrystalline silicon), silver, tantalum, tin,titanium, tungsten, uranium, vanadium, zinc, zirconium, mixturesthereof, and alloys, oxides, or metallic compounds of these elements.

The analyte sensor 400 may be wholly implantable in a user or may beconfigured so that only a portion is positioned within (internal) a userand another portion outside (external) a user. For example, the sensor400 may include a first portion positionable above a surface of the skin405, and a second portion positioned below the surface of the skin. Insuch embodiments, the external portion may include contacts (connectedto respective electrodes of the second portion by traces) to connect toanother device also external to the user such as a transmitter unit.While the embodiment of FIG. 17 shows three electrodes side-by-side onthe same surface of base 404, other configurations are contemplated,e.g., fewer or greater electrodes, some or all electrodes on differentsurfaces of the base or present on another base, some or all electrodesstacked together, electrodes of differing materials and dimensions, etc.Additional sensor configurations are discussed herein.

Data Monitoring and Management Systems

The analyte sensors and associated devices described herein may be usedin the context of one or more data monitoring and management systems.FIG. 18 shows a data monitoring and management system such as, forexample, an analyte (e.g., glucose) monitoring system 100 in accordancewith certain embodiments. Aspects of the subject disclosure are furtherdescribed primarily with respect to glucose monitoring devices andsystems, and methods of glucose detection, for convenience only and suchdescription is in no way intended to limit the scope of the embodiments.It is to be understood that the analyte monitoring system may beconfigured to monitor a variety of analytes at the same time or atdifferent times.

The analyte monitoring system 100 includes an analyte sensor 101 (e.g.,a single-sided or double-sided analyte sensor as described herein), adata processing unit 102 connectable to the sensor 101, and a primaryreceiver unit 104. The terms “sensor control unit” and “data processingunit” are used interchangeably herein. In some instances, the primaryreceiver unit 104 is configured to communicate with the data processingunit 102 via a communication link 103. In certain embodiments, theprimary receiver unit 104 may be further configured to transmit data toa data processing terminal 105 to evaluate or otherwise process orformat data received by the primary receiver unit 104. The dataprocessing terminal 105 may be configured to receive data directly fromthe data processing unit 102 via a communication link 107, which mayoptionally be configured for bi-directional communication. Further, thedata processing unit 102 may include a transmitter or a transceiver totransmit and/or receive data to and/or from the primary receiver unit104 and/or the data processing terminal 105 and/or optionally asecondary receiver unit 106.

Referring again to FIG. 18, the primary receiver unit 104 may include anin vitro analyte meter, a personal computer, a portable computerincluding a laptop or a handheld device (e.g., a personal digitalassistant (PDA), a tablet computer, a telephone including a mobile phone(e.g., a multimedia and Internet-enabled mobile phone including aniPhone™, a Blackberry®, or similar phone), a digital player (e.g., aniPOD™, etc.), a pager, and the like), a drug delivery device (e.g., aninfusion device), or devices including combinations thereof, each ofwhich may be configured for data communication with the data processingunit 102 via a wired or a wireless connection. Additionally, the primaryreceiver unit 104 may further be connected to a data network (not shown)for storing, retrieving, updating, and/or analyzing data correspondingto the detected analyte level of the user.

Also shown in FIG. 18 is an optional secondary receiver unit 106 whichis operatively coupled to the communication link 103 and configured toreceive data transmitted from the data processing unit 102. Thesecondary receiver unit 106 may be configured to communicate with theprimary receiver unit 104, as well as the data processing terminal 105.In certain embodiments, the secondary receiver unit 106 may beconfigured for bi-directional wireless communication with each of theprimary receiver unit 104 and the data processing terminal 105. Asdiscussed in further detail below, in some instances, the secondaryreceiver unit 106 may be a de-featured receiver as compared to theprimary receiver unit 104, for instance, the secondary receiver unit 106may include a limited or minimal number of functions and features ascompared with the primary receiver unit 104. As such, the secondaryreceiver unit 106 may include a smaller (in one or more, including all,dimensions), compact housing or embodied in a device including a wristwatch, arm band, PDA, mp3 player, mobile phone, etc., for example.Alternatively, the secondary receiver unit 106 may be configured withthe same or substantially similar functions and features as the primaryreceiver unit 104. The secondary receiver unit 106 may include a dockingportion configured to mate with a docking cradle unit for placement by,e.g., the bedside for night time monitoring, and/or a bi-directionalcommunication device. A docking cradle may recharge a power supply.

Only one analyte sensor 101, data processing unit 102 and dataprocessing terminal 105 are shown in the embodiment of the analytemonitoring system 100 illustrated in FIG. 18. However, it will beappreciated by one of ordinary skill in the art that the analytemonitoring system 100 may include more than one sensor 101 and/or morethan one data processing unit 102, and/or more than one data processingterminal 105. Multiple sensors may be positioned in a user for analytemonitoring at the same or different times. In certain embodiments,analyte information obtained by a first sensor positioned in a user maybe employed as a comparison to analyte information obtained by a secondsensor. This may be useful to confirm or validate analyte informationobtained from one or both of the sensors. Such redundancy may be usefulif analyte information is contemplated in critical therapy-relateddecisions. In certain embodiments, a first sensor may be used tocalibrate a second sensor.

The analyte monitoring system 100 may be a continuous monitoring system,or semi-continuous, or a discrete monitoring system. In amulti-component environment, each component may be configured to beuniquely identified by one or more of the other components in the systemso that communication conflict may be readily resolved between thevarious components within the analyte monitoring system 100. Forexample, unique IDs, communication channels, and the like, may be used.

In certain embodiments, the sensor 101 is physically positioned in or onthe body of a user whose analyte level is being monitored. The sensor101 may be configured to at least periodically sample the analyte levelof the user and convert the sampled analyte level into a correspondingsignal for transmission by the data processing unit 102. The dataprocessing unit 102 is coupleable to the sensor 101 so that both devicesare positioned in or on the user's body, with at least a portion of theanalyte sensor 101 positioned transcutaneously in some embodiments. Thedata processing unit 102 may include a fixation element, such as anadhesive or the like, to secure it to the user's body. A mount (notshown) attachable to the user and mateable with the data processing unit102 may be used. For example, a mount may include an adhesive surface.The data processing unit 102 performs data processing functions, wheresuch functions may include, but are not limited to, filtering andencoding of data signals, each of which corresponds to a sampled analytelevel of the user, for transmission to the primary receiver unit 104 viathe communication link 103. In some embodiments, the sensor 101 or thedata processing unit 102 or a combined sensor/data processing unit maybe wholly implantable under the skin surface of the user.

In certain embodiments, the primary receiver unit 104 may include ananalog interface section including an RF receiver and an antenna that isconfigured to communicate with the data processing unit 102 via thecommunication link 103, and a data processing section for processing thereceived data from the data processing unit 102 including data decoding,error detection and correction, data clock generation, data bitrecovery, etc., or any combination thereof.

In operation, the primary receiver unit 104 in certain embodiments isconfigured to synchronize with the data processing unit 102 to uniquelyidentify the data processing unit 102, based on, for example, anidentification information of the data processing unit 102, andthereafter, to periodically receive signals transmitted from the dataprocessing unit 102 associated with the monitored analyte levelsdetected by the sensor 101.

Referring again to FIG. 18, the data processing terminal 105 may includea personal computer, a portable computer including a laptop or ahandheld device (e.g., a personal digital assistant (PDA), a tabletcomputer, a telephone including a mobile phone (e.g., a multimedia andInternet-enabled mobile phone including an iPhone™, a Blackberry®, orsimilar phone), a digital player (e.g., an iPOD™, etc.), a pager, andthe like), and/or a drug delivery device (e.g., an infusion device),each of which may be configured for data communication with the receivervia a wired or a wireless connection. Additionally, the data processingterminal 105 may further be connected to a data network (not shown) forstoring, retrieving, updating, and/or analyzing data corresponding tothe detected analyte level of the user.

The data processing terminal 105 may include a drug delivery device(e.g., an infusion device), such as an insulin infusion pump or thelike, which may be configured to administer a drug (e.g., insulin) tothe user, and which may be configured to communicate with the primaryreceiver unit 104 for receiving, among others, the measured analytelevel. Alternatively, the primary receiver unit 104 may be configured tointegrate an infusion device therein so that the primary receiver unit104 is configured to administer an appropriate drug (e.g., insulin) tousers, for example, for administering and modifying basal profiles, aswell as for determining appropriate boluses for administration based on,among others, the detected analyte levels received from the dataprocessing unit 102. An infusion device may be an external device or aninternal device, such as a device wholly implantable in a user.

In certain embodiments, the data processing terminal 105, which mayinclude an infusion device, e.g., an insulin pump, may be configured toreceive the analyte signals from the data processing unit 102, and thus,incorporate the functions of the primary receiver unit 104 includingdata processing for managing the user's insulin therapy and analytemonitoring. In certain embodiments, the communication link 103, as wellas one or more of the other communication interfaces shown in FIG. 18,may use one or more wireless communication protocols, such as, but notlimited to: an RF communication protocol, an infrared communicationprotocol, a Bluetooth enabled communication protocol, an 802.11xwireless communication protocol, or an equivalent wireless communicationprotocol which would allow secure, wireless communication of severalunits (for example, per Health Insurance Portability and AccountabilityAct (HIPPA) requirements), while avoiding potential data collision andinterference.

FIG. 19 shows a block diagram of an embodiment of a data processing unit102 of the analyte monitoring system shown in FIG. 18. User input and/orinterface components may be included or a data processing unit may befree of user input and/or interface components. In certain embodiments,one or more application-specific integrated circuits (ASIC) may be usedto implement one or more functions or routines associated with theoperations of the data processing unit (and/or receiver unit) using forexample one or more state machines and buffers.

The data processing unit 102 may include one or more of: an analoginterface 201, a user input 202, a temperature measurement section 203,a serial communication section 205, an RF transmitter/receiver 206, apower supply 207, and a clock 208, each of which is operatively coupledto a processor 204.

As can be seen in the embodiment of FIG. 19, the analyte sensor 101(FIG. 18) may, in some embodiments, include four contacts, three ofwhich are electrodes: a work electrode (W) 210, a reference electrode(R) 212, and a counter electrode (C) 213, each operatively coupled tothe analog interface 201 of the data processing unit 102. Thisembodiment also shows an optional guard contact (G) 211. Fewer orgreater electrodes may be employed. For example, the counter andreference electrode functions may be served by a singlecounter/reference electrode. In some cases, there may be more than oneworking electrode and/or reference electrode and/or counter electrode,etc.

FIG. 20 is a block diagram of an embodiment of a receiver/monitor unitsuch as the primary receiver unit 104 of the analyte monitoring systemshown in FIG. 18. The primary receiver unit 104 may include, forexample, one or more of: a test strip interface 301, an RF receiver 302,a user input 303, an optional temperature detection section 304, and aclock 305, each of which is operatively coupled to a processing andstorage section 307. The primary receiver unit 104 also includes a powersupply 306 operatively coupled to a power conversion and monitoringsection 308. Further, the power conversion and monitoring section 308 isalso coupled to the processing and storage section 307. Moreover, alsoshown are a receiver serial communication section 309, and anoutput/display 310, each operatively coupled to the processing andstorage section 307. The primary receiver unit 104 may include userinput and/or interface components or may be free of user input and/orinterface components.

In certain embodiments, the test strip interface 301 includes an analytetesting portion (e.g., a glucose level testing portion) to receive ablood (or other body fluid sample) analyte test or information relatedthereto. For example, the test strip interface 301 may include a teststrip port to receive a test strip (e.g., a glucose test strip). Thedevice may determine the analyte level of the test strip, and optionallydisplay (or otherwise notice) the analyte level on the output/display310 of the primary receiver unit 104. Any suitable test strip may beemployed, e.g., test strips that only require a very small amount (e.g.,3 microliters or less, e.g., 1 microliter or less, e.g., 0.5 microlitersor less, e.g., 0.1 microliters or less), of applied sample to the stripin order to obtain accurate glucose information. Additional test stripsthat may be utilized include test strips configured to measure more thanone analyte, e.g., dual analyte test strips. Embodiments of test stripsinclude, e.g., FreeStyle® blood glucose test strips from Abbott DiabetesCare Inc. (Alameda, Calif.) and Precision™, e.g., Precision Xtra™, teststrips from Abbott Diabetes Care Inc. (Alameda, Calif.). Glucoseinformation obtained by an in vitro glucose testing device may be usedfor a variety of purposes, computations, etc. For example, theinformation may be used to calibrate sensor 101, confirm results ofsensor 101 to increase the confidence thereof (e.g., in instances inwhich information obtained by sensor 101 is employed in therapy relateddecisions), etc.

In further embodiments, the data processing unit 102 and/or the primaryreceiver unit 104 and/or the secondary receiver unit 106, and/or thedata processing terminal/infusion device 105 may be configured toreceive the analyte value wirelessly over a communication link from, forexample, a blood glucose meter. In further embodiments, a usermanipulating or using the analyte monitoring system 100 (FIG. 18) maymanually input the analyte value using, for example, a user interface(for example, a keyboard, keypad, touch-screen, voice commands, and thelike) incorporated in one or more of the data processing unit 102, theprimary receiver unit 104, secondary receiver unit 106, or the dataprocessing terminal/infusion device 105.

Additional detailed descriptions are provided in U.S. Pat. Nos.5,262,035; 5,264,104; 5,262,305; 5,320,715; 5,593,852; 6,175,752;6,650,471; 6,746, 582, and 7,811,231, each of which is incorporatedherein by reference in their entirety.

Sensor Electronics Unit

In some embodiments, a sensor electronics unit, such as a sensor controlunit, can be integrated in the sensor, part or all of which issubcutaneously implanted or it can be configured to be placed on theskin of a user. The sensor electronics unit is optionally formed in ashape that is comfortable to the user and which may permit concealment,for example, under a user's clothing. The thigh, leg, upper arm,shoulder, or abdomen are convenient parts of the user's body forplacement of the sensor electronics unit to maintain concealment.However, the sensor electronics unit may be positioned on other portionsof the user's body. One embodiment of the sensor electronics unit has athin, oval shape to enhance concealment. However, other shapes and sizesmay be used.

The particular profile, as well as the height, width, length, weight,and volume of the sensor electronics unit may vary and depends, at leastin part, on the components and associated functions included in thesensor electronics unit. In general, the sensor electronics unitincludes a housing typically formed as a single integral unit that restson the skin of the user. The housing typically contains most or all ofthe electronic components, e.g., the PCB, of the sensor electronicsunit.

The housing of sensor electronics unit may be formed using a variety ofmaterials, including, for example, plastic and polymeric materials, suchas rigid thermoplastics and engineering thermoplastics. Suitablematerials include, for example, polyvinyl chloride, polyethylene,polypropylene, polystyrene, ABS polymers, and copolymers thereof. Thehousing of the sensor electronics unit may be formed using a variety oftechniques including, for example, injection molding, compressionmolding, casting, and other molding methods. Hollow or recessed regionsmay be formed in the housing of the sensor control unit. The electroniccomponents of the sensor electronics unit and/or other items, includinga battery or a speaker for an audible alarm, may be placed in the hollowor recessed areas. In some embodiments, the housing of the sensorelectronics unit is provided as an overmold structure.

The sensor electronics unit is typically attached to the skin of theuser, for example, by adhering the sensor control unit directly to theskin of the user with an adhesive provided on at least a portion of thehousing of the sensor control unit which contacts the skin or bysuturing the sensor electronics unit to the skin through suture openingsin the sensor control unit.

When positioned on the skin of a user, the sensor and the electroniccomponents within a sensor electronics unit, such as a sensor controlunit, may be coupled via conductive contacts. For example, one or moreworking electrodes, counter electrodes (or counter/referenceelectrodes), reference electrodes, and temperature probes may beattached to individual conductive contacts. For example, the conductivecontacts are provided on the interior of the sensor electronics unit.Other embodiments of the sensor control unit have the conductivecontacts disposed on the exterior of the housing. The placement of theconductive contacts may be such that they are in contact with theelectrical contacts on the sensor when the sensor is properly positionedwithin the sensor electronics unit.

As discussed previously herein, one or more sensor connectors, e.g.,conductive rivets, non-conductive rivets, or partially conductiverivets, may be used to couple the sensor and the electronic componentswithin a sensor electronics unit, such as a sensor control unit. Inaddition, one or more sensor connectors, e.g., conductive rivets, may beused to connect an electrode, e.g, a conductive trace of the electrode,from one side of an analyte sensor to the other for coupling with theelectronic components within the sensor electronics unit.

Embodiments of a sensor electronics unit, such as a sensor control unit,according to the present disclosure and its assembly are now describedin more detail with reference to FIGS. 21A-26E which depict variousaspects of a sensor control unit insertion assembly 900. FIGS. 21A-22depict a sensor control unit insertion assembly 900, including a skinpatch 904, an overmold structure 905 and a sensor insertion device 901,which in turn includes an insertion needle 902 and a needle hub assembly903. Skin patch 904 is configured for attachment to the skin of apatient and/or user and includes an adhesive bottom 904B to facilitatesuch attachment. Skin patch 904 also includes an adhesive top 904A forattachment of the skin patch 904 to the overmold structure 905, a needleopening 904D, through which needle 902 may extend, and a thermistoropening 904C, through which a thermistor 909 may be exposed. See, e.g.,FIGS. 22 and 26A-26E. The overmold structure 905 may be made from avariety of suitable materials, e.g., a suitable thermoplastic material(e.g., a moldable polyimide). In one embodiment, overmold structure 905is made from a suitable resin material. The sensor control unitinsertion assembly 900 includes a PCB assembly 906. PCB assembly 906 inturn includes battery contacts 907 for contacting battery 908, athermistor 909, antennae 910 and processor 911. The PCB assembly mayinclude additional optional components as discussed herein, e.g., asdiscussed in the context of data processing unit 102 above.

Sensor control unit insertion assembly 900 also includes sensor support912 which is configured to hold insertion needle 902 and analyte sensor913 together during the insertion process. Sensor support 912 may bemade from a variety of suitable materials including, e.g., a suitablethermoplastic polymer material (e.g., Acetal). Analyte sensor 913 isdepicted in this embodiment as a double-sided analyte sensor, e.g., adouble-sided analyte sensor formed as depicted in analyte sensorassembly 500, as discussed previously herein. However, it should benoted that sensor control unit insertion assembly 900 may be readilymodified to accept an analyte sensor having a different configurationdiscussed herein, e.g., a single-sided analyte sensor as discussedherein.

Sensor control unit insertion assembly 900 also includes a sensorconnector, e.g., a rivet 914, which may be a rivet 600 as discussedpreviously herein. Where the analyte sensor 913 is, e.g., a double-sidedanalyte sensor formed as depicted in analyte sensor assembly 500, therivet functions to physically and electrically connect analyte sensor913 to PCB assembly 906. The rivet physically connects analyte sensor913 to PCB assembly 906 such that electrical contacts 504A and 502B ofthe reference and working electrodes respectively (See FIG. 7) come intophysical and electrical contact with electrical contacts on the topsurface of PCB assembly 906. The rivet 914, made of a conductivematerial in this embodiment, also provides an electrical connectionbetween electrical contact 507A of counter electrode 507 (See FIG. 7)and an electrical contact positioned on the bottom surface of PCBassembly 906 without providing a physical connection between electricalcontact 507A and the electrical contact positioned on the bottom surfaceof PCB assembly 906 (in other words without bringing electrical contact507A into physical contact with the electrical contact positioned on thebottom surface of PCB assembly 906).

In the embodiment shown in FIG. 22 overmold structure 905 is formed overPCB assembly 906 following attachment of sensor support 912, analytesensor 913, and rivet 914 to PCB assembly 906. Following formation ofthe overmold structure 905, skin patch 904 is attached to form thesensor control unit insertion assembly 900.

FIG. 22 shows analyte sensor 913 in a bent configuration such that thedistal end of the analyte sensor, which includes the analyte sensingregion, is positioned at approximately a 90° angle relative to the planeof the PCB assembly 906. This configuration allows the distal end of theanalyte sensor 913 to slideably engage needle 902 of the sensorinsertion device 901 while the proximal end of the analyte sensor 913including the electrode contacts is positioned in a facing relationshiprelative to the plane of PCB assembly 906.

FIGS. 23A-23G provides various views of a portion of the sensor controlunit insertion assembly 900 depicted in FIGS. 21A and 21B including PCBassembly 906, sensor support 912, analyte sensor 913, rivet 914 andsensor insertion device 901. The analyte sensor 913 is shown prior tocutting, e.g., along the cut line shown in FIG. 7, to remove excesssensor material. A larger view of this analyte sensor configuration isshown in FIG. 27. FIGS. 23A-23G also show various components of PCBassembly 906 including battery contacts 907 for contacting battery 908,a thermistor 909, antennae 910 and processor 911. Thermistor 909 isshown in a parallel configuration relative to the plane of the PCBassembly 906. Following formation of overmold structure 905, but priorto attachment of skin patch 904, thermistor 909 is folded under the baseof the overmold structure 905 as shown in FIGS. 19A-25E. Skin patch 904is then attached to the overmold structure leaving a portion ofthermistor 909 exposed to the skin surface.

Sensor Control Unit Electronics

A sensor electronics unit, such as a sensor control unit, typicallyincludes at least a portion of the electronic components that operatethe sensor and the analyte detection/monitoring device and/or system.The electronic components of the sensor electronics unit typicallyinclude a power supply for operating the sensor control unit and thesensor, a sensor circuit for obtaining signals from and operating thesensor, a measurement circuit that converts sensor signals to a desiredformat, and a processing circuit that, at minimum, obtains signals fromthe sensor circuit and/or measurement circuit and provides the signalsto an optional transmitter. In some embodiments, the processing circuitmay also partially or completely evaluate the signals from the sensorand convey the resulting data to an optional transmitter and/or activatean optional alarm system if the analyte level exceeds a threshold. Theprocessing circuit often includes digital logic circuitry.

The sensor electronics unit may optionally contain a transmitter fortransmitting the sensor signals or processed data from the processingcircuit to a receiver/display unit; a data storage unit for temporarilyor permanently storing data from the processing circuit; a temperatureprobe circuit for receiving signals from and operating a temperatureprobe; a reference voltage generator for providing a reference voltagefor comparison with sensor-generated signals; and/or a watchdog circuitthat monitors the operation of the electronic components in the sensorelectronics unit. In some embodiments, the sensor electronics unitincludes an RFID sensor or reader.

Moreover, the sensor electronics unit may also include digital and/oranalog components utilizing semiconductor devices, includingtransistors. To operate these semiconductor devices, the sensor controlunit may include other components including, for example, a bias controlgenerator to correctly bias analog and digital semiconductor devices, anoscillator to provide a clock signal, and a digital logic and timingcomponent to provide timing signals and logic operations for the digitalcomponents of the circuit.

As an example of the operation of these components, the sensor circuitand the optional temperature probe circuit provide raw signals from thesensor to the measurement circuit. The measurement circuit converts theraw signals to a desired format, using for example, a current-to-voltageconverter, current-to-frequency converter, and/or a binary counter orother indicator that produces a signal proportional to the absolutevalue of the raw signal. This may be used, for example, to convert theraw signal to a format that can be used by digital logic circuits. Theprocessing circuit may then, optionally, evaluate the data and providecommands to operate the electronics.

Calibration

Sensors may be configured to require no system calibration or no usercalibration. For example, a sensor may be factory calibrated and neednot require further calibrating. In certain embodiments, calibration maybe required, but may be done without user intervention, i.e., may beautomatic. In those embodiments in which calibration by the user isrequired, the calibration may be according to a predetermined scheduleor may be dynamic, i.e., the time for which may be determined by thesystem on a real-time basis according to various factors, including, butnot limited to, glucose concentration and/or temperature and/or rate ofchange of glucose, etc.

In addition to a transmitter, an optional receiver may be included inthe sensor control unit. In some cases, the transmitter is atransceiver, operating as both a transmitter and a receiver. Thereceiver may be used to receive calibration data for the sensor. Thecalibration data may be used by the processing circuit to correctsignals from the sensor. This calibration data may be transmitted by thereceiver/display unit or from some other source such as a control unitin a doctor's office. In addition, the optional receiver may be used toreceive a signal from the receiver/display units to direct thetransmitter, for example, to change frequencies or frequency bands, toactivate or deactivate the optional alarm system and/or to direct thetransmitter to transmit at a higher rate.

Calibration data may be obtained in a variety of ways. For instance, thecalibration data may be factory-determined calibration measurementswhich can be input into the sensor control unit using the receiver ormay alternatively be stored in a calibration data storage unit withinthe sensor control unit itself (in which case a receiver may not beneeded). The calibration data storage unit may be, for example, areadable or readable/writeable memory circuit. In some cases, a systemmay only need to be calibrated once during the manufacturing process,where recalibration of the system is not required.

If necessary, calibration may be accomplished using an in vitro teststrip (or other reference), e.g., a small sample test strip such as atest strip that requires less than about 1 microliter of sample (forexample Freestyle® or Precision™ blood glucose monitoring test stripsfrom Abbott Diabetes Care, Alameda, Calif.). For example, test stripsthat require less than about 1 nanoliter of sample may be used. Incertain embodiments, a sensor may be calibrated using only one sample ofbody fluid per calibration event. For example, a user need only lance abody part one time to obtain a sample for a calibration event (e.g., fora test strip), or may lance more than one time within a short period oftime if an insufficient volume of sample is firstly obtained.Embodiments include obtaining and using multiple samples of body fluidfor a given calibration event, where glucose values of each sample aresubstantially similar. Data obtained from a given calibration event maybe used independently to calibrate or combined with data obtained fromprevious calibration events, e.g., averaged including weighted averaged,etc., to calibrate. In certain embodiments, a system need only becalibrated once by a user, where recalibration of the system is notrequired.

Alternative or additional calibration data may be provided based ontests performed by a health care professional or by the user. Forexample, it is common for diabetic individuals to determine their ownblood glucose concentration using commercially available testing kits.The results of this test is input into the sensor control unit eitherdirectly, if an appropriate input device (e.g., a keypad, an opticalsignal receiver, or a port for connection to a keypad or computer) isincorporated in the sensor control unit, or indirectly by inputting thecalibration data into the receiver/display unit and transmitting thecalibration data to the sensor control unit.

Other methods of independently determining analyte levels may also beused to obtain calibration data. This type of calibration data maysupplant or supplement factory-determined calibration values.

In some embodiments of the invention, calibration data may be requiredat periodic intervals, for example, every eight hours, once a day, oronce a week, to confirm that accurate analyte levels are being reported.Calibration may also be required each time a new sensor is implanted orif the sensor exceeds a threshold minimum or maximum value or if therate of change in the sensor signal exceeds a threshold value. In somecases, it may be necessary to wait a period of time after theimplantation of the sensor before calibrating to allow the sensor toachieve equilibrium. In some embodiments, the sensor is calibrated onlyafter it has been inserted. In other embodiments, no calibration of thesensor is needed.

Analyte Monitoring Device

In some embodiments of the invention, an analyte monitoring device isprovided which includes a sensor electronics unit, such as a sensorcontrol unit, and a sensor. In these embodiments, the processing circuitof the sensor electronics unit may be configured to determine a level ofthe analyte and activate an alarm system if the analyte level exceeds athreshold value. The sensor electronics unit, in these embodiments, mayinclude an alarm system and may also include a display, such as an LCDor LED display.

A threshold value is exceeded if the datapoint has a value that isbeyond the threshold value in a direction indicating a particularcondition. For example, a datapoint which correlates to a glucose levelof 200 mg/dL exceeds a threshold value for hyperglycemia of 180 mg/dL,because the datapoint indicates that the user has entered ahyperglycemic state. As another example, a datapoint which correlates toa glucose level of 65 mg/dL exceeds a threshold value for hypoglycemiaof 70 mg/dL because the datapoint indicates that the user ishypoglycemic as defined by the threshold value. However, a datapointwhich correlates to a glucose level of 75 mg/dL would not exceed thesame threshold value of 70 mg/dL for hypoglycemia because the datapointdoes not indicate that particular condition as defined by the chosenthreshold value.

An alarm may also be activated if the sensor readings indicate a valuethat is outside of (e.g., above or below) a measurement range of thesensor. For glucose, the physiologically relevant measurement range istypically 40-500 mg/dL, including 40-300 mg/dL and 50-250 mg/dL, ofglucose in the interstitial fluid, and 20-500 mg/dL in blood.

The alarm system may also, or alternatively, be activated when the rateof change or acceleration of the rate of change in analyte levelincrease or decrease reaches or exceeds a threshold rate oracceleration. For example, in the case of a subcutaneous glucosemonitor, the alarm system may be activated if the rate of change inglucose concentration exceeds a threshold value which may indicate thata hyperglycemic or hypoglycemic condition is likely to occur. In somecases, the alarm system is activated if the acceleration of the rate ofchange in glucose concentration exceeds a threshold value which mayindicate that a hyperglycemic or hypoglycemic condition is likely tooccur.

A system may also include system alarms that notify a user of systeminformation such as battery condition, calibration, sensor dislodgment,sensor malfunction, etc. Alarms may be, for example, auditory and/orvisual. Other sensory-stimulating alarm systems may be used includingalarm systems which heat, cool, vibrate, or produce a mild electricalshock when activated.

Drug Delivery System

The subject invention also includes sensors and associated devices usedin sensor-based drug delivery systems. The system may provide a drug tocounteract the high or low level of the analyte in response to thesignals from one or more sensors. Alternatively, the system may monitorthe drug concentration to ensure that the drug remains within a desiredtherapeutic range. The drug delivery system may include one or more(e.g., two or more) sensors, a processing unit such as a transmitter, areceiver/display unit, and a drug administration system. In some cases,some or all components may be integrated in a single unit. Asensor-based drug delivery system may use data from the one or moresensors to provide necessary input for a control algorithm/mechanism toadjust the administration of drugs, e.g., automatically orsemi-automatically. As an example, a glucose sensor may be used tocontrol and adjust the administration of insulin from an external orimplanted insulin pump.

Fiducial Mark

A fiducial mark may be provided in connection with the manufacture of ananalyte sensor, e.g., on a substrate layer of the analyte sensor. Thefiducial mark provides a means by which the location of the electrode,e.g., the electrode trace, may be identified and/or located during themanufacturing process, e.g., to facilitate a singulation step.

Insertion Device

An insertion device can be used to subcutaneously insert the sensor intothe user. The insertion device is typically formed using structurallyrigid materials, such as metal or rigid plastic. Materials may includestainless steel and ABS (acrylonitrile-butadiene-styrene) plastic. Insome embodiments, the insertion device is pointed and/or sharp at thetip to facilitate penetration of the skin of the user. A sharp, thininsertion device may reduce pain felt by the user upon insertion of thesensor. In other embodiments, the tip of the insertion device has othershapes, including a blunt or flat shape. These embodiments may be usefulwhen the insertion device does not penetrate the skin but rather servesas a structural support for the sensor as the sensor is pushed into theskin.

In one embodiment, a sensor insertion device 901 is provided as acomponent of a sensor control unit insertion assembly 900. See, e.g.,FIGS. 21A-26E. Sensor insertion device 901 includes an insertion needle902, e.g., a slotted needle, and a needle hub assembly 903.

Examples of sensor insertion devices and methods of using the same aredisclosed in U.S. application Ser. Nos. 13/071,461; 13/071,487; and Ser.No. 13/071,497, which were all filed on Mar. 24, 2011 and are all titled“Medical Device Inserters And Processes of Inserting And Using MedicalDevices,” the disclosures of each of which are incorporated herein byreference in their entirety.

Embodiments

In some embodiments, an analyte monitoring device is provided, whichincludes: an analyte sensor including a first conductive trace, and adielectric substrate layer having a top surface and a bottom surface,wherein the first conductive trace is positioned on the top surface ofthe dielectric substrate layer; a printed circuit board (PCB) includinga top surface and a bottom surface; and a rivet, wherein the analytesensor is attached to the PCB by the rivet.

In some embodiments of the analyte monitoring device, the rivet includesa conductive material and provides an electrical connection between thefirst conductive trace and the PCB through the dielectric substratelayer. In one such embodiment, the conductive material is copper.

In some embodiments of the analyte monitoring device, the analyte sensorincludes a second conductive trace positioned on the bottom surface ofthe dielectric substrate layer.

In some embodiments of the analyte monitoring device, where the rivetincludes a conductive material and provides an electrical connectionbetween the first conductive trace and the PCB through the dielectricsubstrate layer, the analyte sensor includes a second conductive tracepositioned on the bottom surface of the dielectric substrate layer. Inone such embodiment the conductive material is copper.

In other embodiments, an analyte monitoring device is provided, whichincludes: an analyte sensor including first, second, third and fourthdielectric layers, each layer having a top surface and a bottom surface,a first conductive trace positioned between the top surface of the firstdielectric layer and the bottom surface of the second dielectric layer,a second conductive trace positioned between the bottom surface of thefirst dielectric layer and the top surface of the third dielectriclayer, a third conductive trace positioned between the bottom surface ofthe third dielectric layer and the top surface of the fourth dielectriclayer; a printed circuit board (PCB) including a top surface and abottom surface; and a rivet, wherein the analyte sensor is attached tothe PCB by the rivet.

In some embodiments of the analyte monitoring device, the rivet includesa conductive material and provides an electrical connection between thefirst conductive trace and the PCB through one or more of the dielectriclayers.

In some embodiments of the analyte monitoring device, where the rivetincludes a conductive material and provides an electrical connectionbetween the first conductive trace and the PCB through one or more ofthe dielectric layers, the rivet provides an electrical connectionbetween the first conductive trace and the bottom surface of the PCB. Inone such embodiment, the second electrode trace and the third electrodetrace each include an electrical contact configured to contact the topsurface of the PCB.

In some embodiments of the analyte monitoring device, where the rivetincludes a conductive material and provides an electrical connectionbetween the first conductive trace and the PCB through one or more ofthe dielectric layers, the conductive material is copper.

In some embodiments of the analyte monitoring device, where the rivetincludes a conductive material and provides an electrical connectionbetween the first conductive trace and the PCB through one or more ofthe dielectric layers, the first conductive trace is a counter electrodetrace, the second conductive trace is a working electrode trace, and thethird conductive trace is a reference electrode trace. In one suchembodiment, the working electrode trace and the reference electrodetrace each include an electrical contact configured to contact the topsurface of the PCB.

In some embodiments, a method of making an analyte monitoring device isprovided, which includes: providing an analyte sensor including a firstconductive trace, and a dielectric substrate layer having a top surfaceand a bottom surface, wherein the first conductive trace is positionedon the top surface of the dielectric substrate layer, and wherein thedielectric layer includes a through-hole; providing a printed circuitboard (PCB) including a through-hole, a top surface and a bottomsurface; and attaching the analyte sensor to the PCB by forming a rivetwhich extends through the respective through-holes of the dielectricsubstrate layer and the PCB.

In some embodiments of the method of making the analyte monitoringdevice, the rivet includes a conductive material and provides anelectrical connection between the first conductive trace and the PCBthrough the dielectric substrate layer. In one such embodiment, theconductive material is copper.

In some embodiments of the method of making the analyte monitoringdevice, the analyte sensor includes a second conductive trace positionedon the bottom surface of the dielectric substrate layer.

In some embodiments of the method of making the analyte monitoringdevice, where the rivet includes a conductive material and provides anelectrical connection between the first conductive trace and the PCBthrough the dielectric substrate layer, the analyte sensor includes asecond conductive trace positioned on the bottom surface of thedielectric substrate layer. In one such embodiment, the conductivematerial is copper.

In some embodiments, a method of making an analyte monitoring device isprovided, which includes: providing an analyte sensor including first,second, third and fourth dielectric layers, each dielectric layer havinga top surface and a bottom surface, a first conductive trace positionedbetween the top surface of the first dielectric layer and the bottomsurface of the second dielectric layer, wherein the first dielectriclayer includes a through-hole, a second conductive trace positionedbetween the bottom surface of the first dielectric layer and the topsurface of the third dielectric layer, a third conductive tracepositioned between the bottom surface of the third dielectric layer andthe top surface of the fourth dielectric layer; providing a printedcircuit board (PCB) including a through-hole, a top surface and a bottomsurface; and attaching the analyte sensor to the PCB by forming a rivetwhich extends through the respective through-holes of the firstdielectric layer and the PCB.

In some embodiments of the method of making the analyte monitoringdevice, the rivet includes a conductive material and provides anelectrical connection between the first conductive trace and the PCBthrough one or more of the dielectric layers.

In some embodiments of the method of making the analyte monitoringdevice, where the rivet includes a conductive material and provides anelectrical connection between the first conductive trace and the PCBthrough one or more of the dielectric layers, the rivet provides anelectrical connection between the first conductive trace and the bottomsurface of the PCB. In one such embodiment, the second electrode traceand the third electrode trace each include an electrical contactconfigured to contact the top surface of the PCB.

In some embodiments of the method of making the analyte monitoringdevice, where the rivet includes a conductive material and provides anelectrical connection between the first conductive trace and the PCBthrough one or more of the dielectric layers, the conductive material iscopper.

In some embodiments of the method of making the analyte monitoringdevice, where the rivet includes a conductive material and provides anelectrical connection between the first conductive trace and the PCBthrough one or more of the dielectric layers, the first conductive traceis a counter electrode trace, the second conductive trace is a workingelectrode trace, and the third conductive trace is a reference electrodetrace. In one such embodiment, the working electrode trace and thereference electrode trace each include an electrical contact configuredto contact the top surface of the PCB.

In some embodiments, an analyte sensor is provided, which includes: adielectric base substrate having a proximal end, a distal end, a firstside edge extending from the proximal end to the distal end, a secondside edge extending from the proximal end to the distal end, and a firstthickness; a first conductive layer positioned on the dielectric basesubstrate, the first conductive layer having a length (L₁) and a width(W₁); a first dielectric cover layer positioned to cover at least aportion of the first conductive layer, wherein the first dielectriccover layer has a proximal end, a distal end, a first side edgeextending from the proximal end to the distal end, a second side edgeextending from the proximal end to the distal end, and a secondthickness which is less than that of the dielectric base substrate; asecond conductive layer positioned on the first dielectric cover layer,the second conductive layer having a length (L₂) and a width (W₂); and asecond dielectric cover layer positioned to cover at least a portion ofthe second conductive layer, wherein the second dielectric cover layerhas a second thickness which is less than that of the dielectric basesubstrate, wherein W₁ is less than W₂ or W₂ is less than W₁.

In some embodiments of the analyte sensor, when W₁ is less than W₂ thefirst conductive layer is spaced away from the first and second sideedges of the dielectric base substrate. In one such embodiment, thesecond conductive layer terminates at a distal end which is spaced backfrom the distal end of the first conductive layer.

In some embodiments of the analyte sensor, when W₂ is less than W₁ thesecond conductive layer is spaced away from the first and second sideedges of the first dielectric cover layer. In one such embodiment, thesecond conductive layer terminates at a distal end which is spaced backfrom the distal end of the first conductive layer.

In some embodiments, an analyte monitoring device is provided whichincludes: an analyte sensor including a first electrode, and adielectric substrate layer having a first surface and a second surface,wherein the first electrode is positioned on the first surface of thedielectric substrate layer; a printed circuit board (PCB) comprising afirst surface and a second surface; and a rivet, wherein the analytesensor is attached to the PCB by the rivet.

In some embodiments of the analyte monitoring device, the rivet includesa conductive material and provides an electrical connection between thefirst electrode and the PCB through the dielectric substrate layer. Insome embodiments, the conductive material is copper.

In some embodiments of the analyte monitoring device, the analyte sensorincludes a second electrode positioned on the second surface of thedielectric substrate layer.

In some embodiments of the analyte monitoring device the first electrodecomprises carbon or gold.

In some embodiments, an analyte monitoring device includes: an analytesensor including first, second, third and fourth dielectric layers, eachlayer having a first surface and a second surface, a first electrodepositioned between the first surface of the first dielectric layer andthe second surface of the second dielectric layer, a second electrodepositioned between the second surface of the first dielectric layer andthe first surface of the third dielectric layer, a third electrodepositioned between the second surface of the third dielectric layer andthe first surface of the fourth dielectric layer; a printed circuitboard (PCB) comprising a first surface and a second surface; and arivet, wherein the analyte sensor is attached to the PCB by the rivet.

In some embodiments of the analyte monitoring device, the rivet includesa conductive material and provides an electrical connection between thefirst electrode and the PCB through one or more of the dielectriclayers.

In some embodiments of the analyte monitoring device, the rivet providesan electrical connection between the first electrode and the secondsurface of the PCB.

In some embodiments of the analyte monitoring device, the secondelectrode and the third electrode each include an electrical contactconfigured to contact the first surface of the PCB.

In some embodiments of the analyte monitoring device, the firstelectrode is a counter electrode, the second electrode is a workingelectrode, and the third electrode is a reference electrode.

In some embodiments of the analyte monitoring device, the workingelectrode and the reference electrode each include an electrical contactconfigured to contact the first surface of the PCB.

In some embodiments of the analyte monitoring device the first, second,and third electrodes comprise carbon or gold.

In some embodiments, a method of making an analyte monitoring deviceincludes: providing an analyte sensor including a first electrode, and adielectric substrate layer having a first surface and a second surface,wherein the first electrode is positioned on the first surface of thedielectric substrate layer, and wherein the dielectric layer includes athrough-hole; providing a printed circuit board (PCB) comprising athrough-hole, a first surface and a second surface; and attaching theanalyte sensor to the PCB by forming a rivet which extends through therespective through-holes of the dielectric substrate layer and the PCB.

In some embodiments of the method of making the analyte monitoringdevice, the rivet includes a conductive material and provides anelectrical connection between the first electrode and the PCB throughthe dielectric substrate layer.

In some embodiments of the method of making the analyte monitoringdevice, the conductive material is copper.

In some embodiments of the method of making the analyte monitoringdevice, the analyte sensor includes a second electrode positioned on thesecond surface of the dielectric substrate layer.

In some embodiments of the method of making the analyte monitoringdevice, the first electrode comprises carbon or gold.

In some embodiments, a method of making an analyte monitoring deviceincludes: providing an analyte sensor including first, second, third andfourth dielectric layers, each dielectric layer having a first surfaceand a second surface, a first electrode positioned between the firstsurface of the first dielectric layer and the second surface of thesecond dielectric layer, wherein the first dielectric layer includes athrough-hole, a second electrode positioned between the second surfaceof the first dielectric layer and the first surface of the thirddielectric layer, a third electrode positioned between the secondsurface of the third dielectric layer and the first surface of thefourth dielectric layer; providing a printed circuit board (PCB)comprising a through-hole, a first surface and a second surface; andattaching the analyte sensor to the PCB by forming a rivet which extendsthrough the respective through-holes of the first dielectric layer andthe PCB.

In some embodiments of the method of making an analyte monitoringdevice, the rivet includes a conductive material and provides anelectrical connection between the first electrode and the PCB throughone or more of the dielectric layers.

In some embodiments of the method of making an analyte monitoringdevice, the rivet provides an electrical connection between the firstelectrode and the second surface of the PCB.

In some embodiments of the method of making an analyte monitoringdevice, the second electrode and the third electrode each include anelectrical contact configured to contact the first surface of the PCB.

In some embodiments of the method of making an analyte monitoringdevice, the conductive material is copper.

In some embodiments of the method of making an analyte monitoringdevice, the first electrode is a counter electrode, the second electrodeis a working electrode, and the third electrode is a referenceelectrode.

In some embodiments of the method of making an analyte monitoringdevice, the working electrode and the reference electrode each includean electrical contact configured to contact the first surface of thePCB.

In some embodiments of the method of making an analyte monitoringdevice, the first, second, and third electrodes comprise carbon or gold.

In some embodiments, an analyte sensor includes: a dielectric basesubstrate having a proximal end, a distal end, a first side edgeextending from the proximal end to the distal end, a second side edgeextending from the proximal end to the distal end, and a firstthickness; a first conductive layer positioned on the dielectric basesubstrate, the first conductive layer having a length (L₁) and a width(W₁); a first dielectric cover layer positioned to cover at least aportion of the first conductive layer, wherein the first dielectriccover layer has a proximal end, a distal end, a first side edgeextending from the proximal end to the distal end, a second side edgeextending from the proximal end to the distal end, and a secondthickness which is less than that of the dielectric base substrate; asecond conductive layer positioned on the first dielectric cover layer,the second conductive layer having a length (L₂) and a width (W₂); and asecond dielectric cover layer positioned to cover at least a portion ofthe second conductive layer, wherein the second dielectric cover layerhas a second thickness which is less than that of the dielectric basesubstrate, wherein W₁ is less than W₂ or W₂ is less than W₁.

In some embodiments of the analyte sensor, when W₁ is less than W₂ thefirst conductive layer is spaced away from the first and second sideedges of the dielectric base substrate.

In some embodiments of the analyte sensor, the second conductive layerterminates at a distal end which is spaced back from the distal end ofthe first conductive layer.

In some embodiments of the analyte sensor, when W₂ is less than W₁ thesecond conductive layer is spaced away from the first and second sideedges of the first dielectric cover layer.

In some embodiments of the analyte sensor, the second conductive layerterminates at a distal end which is spaced back from the distal end ofthe first conductive layer.

In some embodiments of the analyte sensor, the first and secondconductive layers comprise carbon or gold.

In some embodiments, a system includes: a sensor connector; an analytesensor; and an electronics unit, wherein the sensor connector isconfigured to physically, electrically, or physically and electricallyconnect the analyte sensor and the electronics unit.

In some embodiments of the system, the sensor connector is a rivetcomprising a first end and a second end.

In some embodiments of the system, the rivet includes a conductivematerial.

In some embodiments of the system, the rivet physically and electricallyconnects the analyte sensor and the electronics unit.

In some embodiments of the system, the rivet includes a rivet headpositioned at the first end and a shaft extending from the rivet head tothe second end, and wherein an angle formed by the rivet head and theshaft is less than 90 degrees.

In some embodiments of the system, the rivet includes a rivet headpositioned at the first end and a shaft extending from the rivet head tothe second end, and wherein the shaft includes a hole at the second end,the hole extending from the second end towards the first end terminatingbetween the first end and the second end.

As will be apparent to those of skill in the art upon reading thisdisclosure, each of the individual embodiments described and illustratedherein has discrete components and features which may be readilyseparated from or combined with the features of any of the other severalembodiments without departing from the scope or spirit of the presentinvention. Any recited method can be carried out in the order of eventsrecited or in any other order which is logically possible. This isintended to provide support for all such combinations.

Each of the various references, presentations, publications, provisionaland/or non-provisional U.S. Patent Applications, U.S. Patents, non-U.S.Patent Applications, and/or non-U.S. Patents that have been identifiedherein, are incorporated herein by reference in its entirety and for allpurposes.

Other embodiments and modifications within the scope of the presentdisclosure will be apparent to those skilled in the relevant art.Various modifications, processes, as well as numerous structures towhich the embodiments of the invention may be applicable will be readilyapparent to those of skill in the art to which the invention is directedupon review of the specification. Various aspects and features of theinvention may have been explained or described in relation tounderstandings, beliefs, theories, underlying assumptions, and/orworking or prophetic examples, although it will be understood that theinvention is not bound to any particular understanding, belief, theory,underlying assumption, and/or working or prophetic example. Althoughvarious aspects and features of the invention may have been describedlargely with respect to applications, or more specifically, medicalapplications, involving diabetic humans, it will be understood that suchaspects and features also relate to any of a variety of applicationsinvolving non-diabetic humans and any and all other animals. Further,although various aspects and features of the invention may have beendescribed largely with respect to applications involving partiallyimplanted sensors, such as transcutaneous or subcutaneous sensors, itwill be understood that such aspects and features also relate to any ofa variety of sensors that are suitable for use in connection with thebody of an animal or a human, such as those suitable for use as fullyimplanted in the body of an animal or a human. Finally, although thevarious aspects and features of the invention have been described withrespect to various embodiments and specific examples herein, all ofwhich may be made or carried out conventionally, it will be understoodthat the invention is entitled to protection within the full scope ofthe appended claims.

What is claimed is:
 1. A glucose monitoring device comprising: a sensorelectronics unit including a housing, and a printed circuit boarddisposed within the housing and having a plurality of electricalcontacts including a first electrical contact; a transcutaneous glucosesensor assembly including a distal portion having a working electrodeand proximal portion having a working-electrode contact in electricalcommunication with the working electrode; and a conductive sensorconnector electrically connecting the working-electrode contact with thefirst electrical contact; wherein the conductive sensor connectorextends through a hole in the proximal portion of the transcutaneousglucose sensor assembly and through a hole in the printed circuit board.2. The glucose monitoring device of claim 1, wherein the conductivesensor connector comprises a pin.
 3. The glucose monitoring device ofclaim 2, wherein the pin comprises a head portion and a shaft portion,the shaft portion extending through the hole of the proximal portion ofthe transcutaneous glucose sensor assembly.
 4. The glucose monitoringdevice of claim 3, wherein the shaft portion extends through the hole inthe printed circuit board.
 5. The glucose monitoring device of claim 3,wherein the shaft portion and the head portion form an angle of between10 and 170 degrees.
 6. The glucose monitoring device of claim 3, whereinthe shaft portion and the head portion form an angle of 90 degrees. 7.The glucose monitoring device of claim 1, wherein the conductive sensorconnector comprises a post.
 8. The glucose monitoring device of claim 1,wherein the hole in the proximal portion of the transcutaneous glucosesensor assembly extends through the working-electrode contact.
 9. Theglucose monitoring device of claim 1, wherein the hole in the a printedcircuit board extends through the electrical contact.
 10. The glucosemonitoring device of claim 1, wherein the working-electrode contactextends around at least a portion of the hole in the proximal portion ofthe transcutaneous glucose sensor assembly.
 11. The glucose monitoringdevice of claim 1, wherein the first electrical contact extends aroundat least a portion of the hole in the printed circuit board.
 12. Theglucose monitoring device of claim 1, wherein the conductive sensorconnector comprises a conductive material selected from the groupconsisting of gold, silver, platinum, aluminum, copper, and brass. 13.The glucose monitoring device of claim 1, wherein the conductive sensorconnector is further configured to provide alignment between thetranscutaneous glucose sensor assembly and the sensor electronics unit.14. The glucose monitoring device of claim 1, wherein the conductivesensor connector is further configured to physically connect thetranscutaneous glucose sensor assembly and the sensor electronics unit.15. The glucose monitoring device of claim 11, wherein thetranscutaneous glucose sensor assembly comprises a bend between theproximal portion and the distal portion.
 16. The glucose monitoringdevice of claim 15, wherein the printed circuit board defines a plane,and the proximal portion of the transcutaneous glucose sensor assemblyis positioned in a facing relationship relative to the plane of theprinted circuit board.
 17. The glucose monitoring device of claim 16,wherein the distal portion of the transcutaneous glucose sensor assemblyis positioned at approximately a 90o angle relative to the plane of theprinted circuit board.
 18. The glucose monitoring device of claim 1,wherein the transcutaneous glucose sensor assembly comprises a wiresensor.
 19. The glucose monitoring device of claim 1, wherein the wiresensor comprises a core conductive wire.
 20. The glucose monitoringdevice of claim 1, further comprising a second conductive sensorconnector; wherein the distal portion of the transcutaneous glucosesensor assembly comprises a second electrode and the proximal portion ofthe transcutaneous glucose sensor assembly comprises a second-electrodecontact in electrical communication with the second electrode; whereinthe plurality of electrical contacts comprises a second electricalcontact; and wherein the second conductive sensor connector electricallyconnects the second-electrode contact with the second electricalcontact.
 21. The glucose monitoring device of claim 20, wherein thesecond conductive sensor connector extends through a second hole in theproximal portion of the transcutaneous glucose sensor assembly andthrough a second hole in the printed circuit board.
 22. The glucosemonitoring device of claim 20, wherein the second conductive sensorconnector comprises a pin.
 23. The glucose monitoring device of claim22, wherein the pin comprises a head portion and a shaft portion, theshaft portion of pin extending through the second hole of the proximalportion of the transcutaneous glucose sensor assembly.
 24. The glucosemonitoring device of claim 1, further comprising an adhesive coupled tothe housing of the sensor electronics unit and configured to attach thesensor electronics unit to skin of a user.